Giao Trinh Cong Nghe Va Thiet Bi Luyen Thep - Hoang Cong Minh - 100306 - 1

I HC NNG TRNG I HC BCH KHOA
HONG MINH CNG
Gio trnh CNG NGH V THIT B LUYN THP
NNG - 2007
Su t m b i: www.daihoc.com.vn
Li ni u Cng vi s tin b vt bc trong khoa hc v cng ngh, c bit l trong lnh vc vt liu, nhiu loi vt liu mi c nghin cu v ng dng trong sn xut. Tuy nhin, cho n nay thp vn c coi l mt trong nhng vt liu ch yu dng trong ch to my mc, thit b cng nh trong nhiu kt cu v cng trnh chu lc khc. Hng nm, nc ta s dng mt lng ln thp xy dng trong cc cng trnh xy dng, cng trnh giao thng vn ti v mt lng khng nh thp ch to ch to my mc, thit b phc v ngnh c kh, ngnh ch to t, ngnh ha cht v nhiu ngnh khc m mt phn ln trong s vn phi nhp ngoi. Trong nhng nm ti, p ng nhu cu xy dng v sn xut trong nc, mt nhim v cp bch l nhanh chng pht trin ngnh thp, trong vn luyn v c phi ng mt vai tr ht sc quan trng. pht trin ngnh thp, song song vi vic u t i mi thit b, i mi cng ngh th mt vn ht sc cn thit l pht trin i ng cn b k thut chuyn ngnh c kin thc chuyn mn v c nng lc thc t vng. Gio trnh Cng ngh v thit b luyn thp c bin son gm 8 chng, trnh by nhng kin thc c bn v thit b v cng ngh luyn thp nh c s l thuyt qu trnh luyn thp; nguyn, nhin vt liu dng trong luyn thp; thit b v cng ngh luyn thp trong cc loi l khc nhau; thit b v cng ngh c phi cn Gio trnh c dng lm ti hc tp cho sinh vin chuyn ngnh C kh Luyn cn thp thuc Khoa C kh, trng i hc Bch Khoa - i hc Nng. Mt khc, vi ni dung lin quan n nhiu vn thc t sn xut, gio trnh cng c th dng lm ti liu tham kho b ch cho cc cn b k thut ang lm vic trong lnh vc sn xut thp. Do gio trnh c bin son ln u, mi dung bao qut rng, ti liu tham kho hn ch, chc chn cn nhiu sai st. gio trnh c hon thin hn, rt mong s gp ca bn b ng nghip, mi kin ng gp xin gi v khoa C kh, trng i hc Bch Khoa - i hc Nng. Tc gi
Chng I KHI QUT CHUNG

1.1. Khi nim v phn loi thp 1.1.1. Khi nim Thp l hp kim ca st vi cacbon v mt s nguyn t kim loi hay phi kim khc, trong hm lng cacbon khng vt qu mt gii hn nht nh. St l nguyn t c bn v cacbon l nguyn t tp cht chnh nh hng quyt nh n t chc v tnh cht ca thp. Cc nguyn t khc c a vo thp do c im ca cng ngh nu luyn hoc do hp kim ha c th l tp cht c li cng c th l tp cht c hi. Trong thp cacbon, ngoi st v cacbon, thng cha mt lng nht nh cc nguyn t khc nh Si, Mn, P, S trong Si, Mn l tp cht c li cn P, S l tp cht c hi cn hn ch. Cht lng ca thp c nh gi qua cc ch tiu: + bn b (kG/mm2); + Gii hn chy s (kG/mm2); + gin di (%); + co tht (%); + dai va p ak (kj/mm2). Ngoi ra cn c nhng tnh nng c bit khc nh: + Tnh dn t; + Tnh chng mi mn; + Tnh chu nhit; + Tnh chng r. 1.1.2. Phn loi thp a) Phn loi theo thnh phn ha hc Theo thnh phn ha hc, thp c chia ra: thp cacbon v thp hp kim.
0,2 % kG/mm2 b s
Hnh 1.1 Gin ko ca thp
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Thp cacbon: hm lng cacbon <2,0%, ngoi ra cn c: 0,1 0,8 %Mn; 0,5 1,0 %Si; <0,06%P; <0,02%S. Theo hm lng cacbon trong thp, thp cacbon li c chia ra: + Thp cacbon thp : C < 0,25%; + Thp cacbon trung bnh : C = 0,25 0,5%; + Thp cacbon trung bnh: C = 0,5 2,0 %. Thp hp kim: ngoi st, cacbon v cc nguyn t thng c, trong thnh phn ca thp cn c a vo mt hoc ng thi mt s nguyn t khc (gi l nguyn t hp kim ha) vi hm lng ln lm thay i t chc ca thp do thay i tnh cht ca thp. Theo tng lng cc nguyn t hp kim c trong thp, ngi ta chia ra: + Thp hp kim thp: hp kim < 5%; + Thp hp kim trung bnh: hp kim = 5 10%; + Thp hp kim cao: hp kim 10%; b) Phn loi theo t chc t vi Theo t chc t vi, thp c phn ra: + Thp peclit; + Thp mactenxit; + Thp austenit; + Thp cacbit. c) Phn loi theo cng dng Theo cng dng, thp c chia ra: + Thp thng thng: hay cn gi l thp cht lng thng, ch yu dng trong cc cng trnh xy dng, giao thng vn ti... thng l thp cacbon thp. Yu cu c bn l bn v do ca thp. + Thp kt cu: dng ch to cc chi tit my, thng l thp cacbon thp v trung bnh, thp hp kim thp. Yu cu c bn l c tnh tng hp tt, thnh phn ha hc khng ch chnh xc.
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+ Thp dng c: dng ch to cc loi dng c ct, dng c o, khun dp ... thng l thp cacbon cao hoc thp hp kim. Yu cu c bn ca thp l cng cao, bn tng i tt, chu mi mn. + Thp c bit: l thp c tnh cht l ha c bit nh: chu n mn (khng g), chu nng, chu mi mn, chu axit... d) Phn loi theo cng ngh nu luyn Theo thit b nu luyn, thp c chia ra: + Thp l mactanh; + Thp l thi; + Thp l in ... Theo mc kh oxy khi nu luyn, thp c chia ra: + Thp si: kh oxy cha trit ; + Thp lng: kh oxy trit ; + Thp na lng: mc kh oxy nm gia thp lng v thp si. 1.1.3. K hiu ca thp Theo TCVN, thp c k hiu nh sau: + Thp cacbon thng dng: CT31; CT34; ...;CT51, trong CT ch loi thp cacbon thng dng, con s tip theo ch bn ko ca thp tnh bng kG/mm2. + Thp cacbon kt cu: C08; C12; ...;C20; C15; ...; C50, trong C ch loi thp cacbon kt cu, con s tip theo ch phn vn cacbon trong thp. + Thp dng c: CD70; CD80; ...; CD130, trong CD ch loi thp cacbon dng c, con s tip theo ch phn vn cacbon trong thp. + Thp hp kim: 60Si2; 55Mn; 110Mn13; 30CrNiW; 20Cr18Ni12Mo3Ti ... trong con s u tin ch phn vn cacbon c trong thp; cc k hiu tip theo l k hiu tn nguyn t hp kim v ngay sau k hiu l con s ch phn trm nguyn t c trong thp, trng hp nguyn t hp kim c hm lng xp x 1% th khng ghi con s.
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1.2. Lu trnh sn xut thp Tu thuc nguyn liu dng sn xut thp, c th s dng hai lu trnh trnh khc nhau: + Lu trnh dng nguyn liu qung; + Lu trnh dng st thp ph; Hnh 1.1 trnh by s lu trnh luyn thp.
Kh l cao
Qung st
Hon nguyn trc tip
Hon nguyn th lng
Hon nguyn th rn St thp ph
Khng kh
Gang luyn thp X Gang c

L thi
xy
L in L tinh luyn
Thp c
c phi
Cn
Hnh 1.1 S lu trnh sn xut thp
Theo quy trnh ph bin hin nay, nguyn liu qung cng vi nhin liu v cht tr dung c a vo l cao sn xut ra gang luyn thp. Gang luyn thp c c thnh thi hoc chuyn trc tip th lng vo cc l luyn luyn thnh thp v c phi cn. Qung st: qung luyn thp gm qung st nguyn khai hm lng st 66% hoc qung thiu kt dng cc. -8-
Nhin liu: luyn gang dng nhin liu chnh l than cc l nhin liu nhn to c bn c v bn nhit cao, hm lng tro t. Cht tr dung: to x khi luyn gang, thng dng vi. Sn phm chnh ca l cao l gang luyn thp cha <1,5%Si (chim 90%) v gang c cha 1,5%Si (chim 10%). Sn phm ph gm: x v kh l cao. X c thnh phn ch yu l Al2O3 v SiO2, thng c tn dng trong cng nghip sn xut xi mng. Kh l cao cha CO, CO2, N2, SO2... vi CO l thnh phn chy, c dng lm nhin liu kh. luyn thp c th dng l thi hoc l in. L thi ch yu dng cho qu trnh luyn t qung, nguyn liu l gang lng luyn thp c chuyn n t l cao. L in ch yu dng nguyn liu st thp ph. 1.3. Phn loi l luyn thp Theo kt cu, l luyn thp c chia ra: + L mactanh; + L thi; + L in h quang; + L in cm ng; + L in x ... Theo nng lng s dng, l luyn thp c chia ra: + L dng nhin liu: s dng nhit do t chy nhin liu (l mactanh); + L dng nng lng in: bin i in nng thnh nhit nng (l in h quang, l in cm ng); + L t pht nhit: s dng nhit ca cc phn ng ha hc sinh ra trong qu trnh luyn thp (l thi); Theo tnh cht ca vt liu xy l, l luyn thp c chia ra: + L axit: lp lm vic ca tng l c tnh axit; + L baz: lp lm vic ca tng l c tnh baz. -9-
Chng II NGUYN VT LIU DNG LUYN THP

2.1. Nguyn vt liu Nguyn vt liu kim loi dng trong sn xut thp gm cc loi: gang thi (hoc gang lng) luyn thp; thp vn, hi liu v cc hp kim fer. a) Gang thi luyn thp: gang thi luyn thp c sn xut t l cao, thnh phn ph thuc vo loi l s dng. Bng 2.1 v 2.2 cho thnh phn ca mt s loi gang thi luyn thp ca Nga (Lin X c) v Vit Nam. Gang thi M1, M2 (hoc GM1, GM2) dng cho l mactanh, gang thi 1, 2 dng cho l Betsme, gang thi T dng cho l Tmat Bng 2.1 Thnh phn gang thi luyn thp (Lin X c) Thnh phn ha hc (%) Mc gang M1 M2 1
2 T
2.1.1. Nguyn vt liu kim loi
Mn Si
0,761,25 0,75 1,261,75 0,071,25 0,200,60 Nhm I 1,0 1,0 Nhm II 1,011,75 1,011,75 Loi A 0,15 0,15 -
P
Loi 0,20 0,20 0,07 0,07 1,52,0 Loi B 0,30 0,30 Loi I 0,03 0,03 -
S
Loi II 0,05 0,05 0,04 0,06 0,08 Loi III 0,07 0,07 -
0,60 1,20 0,5 0,80 0,8 0 1,30
Bng 2.2 Thnh phn gang thi luyn thp (Cng ty gang thp Thi Nguyn) Thnh phn ha hc (%) Mc gang
GM1
Mn Si
0,75 1,0 I II 1,01 n 1,75 III 1,76 n 2,50 0,03 I
P
II 0,05 III 0,07 I 0,15
S
II 0,20 III 0,30
GM2 0,761,25
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b) Thp vn: thp vn (hay cn gi l thp ph) l cc chi tit my bng thp hng, cc ro vn, u tha trong qu trnh gia cng c kh, rn dp... c thu mua t ngoi v. Thp ph thng c chia thnh hai loi l thp vn cacbon v thp vn hp kim. Thp vn cacbon (cc ro vn t thp cacbon) c dng nu thp cacbon v thp hp kim. Thp vn nn chn dng cc, dng tm kch thc nh hn kch thc l (chiu dy nn 10 mm), khng nn chn dng ng bt kn, thp vn rt r nhiu, dnh du m, axit, kim ... Thp vn hp kim (cc ro vn t thp hp kim) c tn dng nu cc mc thp hp kim. Thp vun hp kim c phn loi theo nhm nguyn t hp kim ph hp vi thnh phn thp cn nu, vi cc ro vn thp hp kim cha nguyn t d b oxy ha ch nn dng khi nu khng c giai on oxy ha. c) Hi liu: l thp h thng rt, ngt, thp ri vi trong qu trnh c... c thu hi nu li. Hi liu yu cu phi sch, t dnh t ct. d) Hp kim fer: hp kim ca st vi mt hoc mt s nguyn t hp kim nh Si, Mn, Cr ... c dng iu chnh thnh phn, hp kim ha v kh oxy. Thnh phn mt s mc fer ph bin cho cc bng 2.3 n bng 2.7. Bng 2.3 Thnh phn hp kim fermangan (Vit Nam) Loi fermangan Cc bon thp Cc bon trung bnh Cc bon cao K hiu Mn 0 Mn 1 Mn 2 Mn 3 Mn 4 Mn 5 Mn 6 Mn 80 78 75 78 75 70 65 Thnh phn ha hc (%) C 0,50 1,0 1,5 7,0 7,0 7,0 7,0 Si 2,0 2,5 2,5 2,5 2,5 3,0 4,0 P 0,30 0,30 0,35 0,38 0,45 0,45 0,45 S 0,03 0,03 0,03 0,03 0,03 0,03 0,03
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Bng 2.4 Thnh phn hp kim fersilic (Thi Nguyn) Loi fer K hiu Thnh phn ha hc (%) Si 40 47 7080 8795 Mn 0,80 0,70 0,50 Cr 0,50 0,50 0,20 P 0,05 0,05 0,04 S 0,04 0,04 0,03
Fersilic 45 Si 45 Fersilic 75 Si 75 Fersilic 90 Si 90
Bng 2.5 Thnh phn hp kim silicmangan (Thi Nguyn) Loi fer Silicmangan 20 Silicmangan 17 Silicmangan 14 K hiu SiMn20 SiMn17 SiMn14 Thnh phn ha hc (%) Si 20 17 14 Mn 65 65 60 C 1,0 1,7 2,5 P 0,1 0,1 0,2
Bng 2.6 Thnh phn siliccan xi (Lin X c) Loi fer K hiu KaCu0 Siliccanxi KaCu1 KaCu2 Thnh phn ha hc (%) Ca 31 28 23 CaSi 90 90 85 Al 1,5 2,0 3,0 P 0,05 0,05 0,05 S 0,04 0,04 0,07
Bng 2.7 Thnh phn fercrm (Lin X c) Loi fer K hiu Xp 0000 Xp 000 Fercrm Xp 00 Xp 0 Thnh phn ha hc (%) C 0,06 0,071,0 0,110,15 0,160,25 Si 1,5 1,5 1,5 0,2 - 12 P 0,06 0,06 0,06 0,06 Cr 65 65 60 60 S 0,03 0,04 0,04 0,04
Xp 01 Xp 1 Xp 2 Fercrm Xp 3 Xp 4 Xp 5
0,260,50 0,501,0 1,12,0 2,14,0 4,16,5 6,68,0
2,0 2,53,0 2,53,0 2,53,0 2,05,0 2,05,0
0,1 0,10 0,10 0,10 0,07 0,07
60 60 60 65 65 65
0,04 0,04 0,04 0,04 0,04 0,04
Ngoi cc nguyn liu trn, hin nay ngi ta cn dng st xp ln nguyn liu luyn thp, l sn phm ca qu trnh hon nguyn trc tip qung st bng kh thin nhin hoc bng than gy, hm lng st trn 90%. 2.1.2. Cht oxy ha Thng dng l qung st v oxy. Qung st: thng dng loi c hm lng oxyt st cao v cc oxyt khc thp. Yu cu k thut i vi qung st dng lm cht oxy ha khi luyn thp nu bng 2.8. Bng 2.8 Yu cu k thut i vi qung st dng lm cht oxy ha Loi l L Mactanh L thi nh L in Thnh phn ha hc (%) Fe 50 50 55 SiO2 10 10 8 S 0,2 0,2 0,1 P 0,1 <0,5 m (%) C cc (mm) 30250 1050 3100
Ngoi qung st c th tn dng vy oxyt st lm cht oxy ha, yu cu i vi vy oxyt st dng lm cht oxy ha khi luyn thp nu bng 2.9. Bng 2.9 Yu cu k thut i vi vy st dng lm cht oxy ha Tn gi Fe Vy oxyt st >70 Thnh phn ha hoc (%) SiO2 <3 - 13 S <0,04 P 0,05 m (%) <4
Oxy: dng oxy trong khng kh hoc oxy k thut hm lng oxy 98%. Yu cu i vi oxy k thut dng trong luyn thp nu bng 2.10. Bng 2.10 Yu cu i vi oxy k thut dng trong luyn thp Loi l L in L thi nh L thi sn 2.1.3. Cht to x c s dng nhiu l vi, ct thch anh, vn samt, ngoi ra cn dng hunh thch, bcxit Vi: thnh phn chnh l CaO, lng dng cng ln th baz ca x cng cao. Yu cu i vi vi dng lm cht to x khi luyn thp nu bng 2.11. Bng 2.11 Yu cu i vi vi dng lm cht to x khi luyn thp Thnh phn ha hc (%) Loi l L Mactanh L thi L in CaO 85 85 85 SiO2 3,5 3,5 2 MgO 5 5 52 3 Fe2O3+Al2O3 S < 0,2 0,2 0,15 <0,3 m (%) C cc (mm) 30150 550 2060 Hm lng O2 (%) > 98 99,5 95 96 m (g/m ) <3 Kh ht m 3
p sut s dng (kG/cm2) 5 10 6 12 3
Hunh thch: thnh phn chnh l CaF2, khi a hunh thch vo x s to thnh cc phc cht c nhit nng chy thp (xAl2O3.yCaO, xSiO2.yCaO, xFeO.yCaO... ) lm gim mnh nhit chy ca x (nhit nng chy vo khong 1100 1300oC).
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Bng 2.12 Yu cu i vi hunh thc dng lm cht to x khi luyn thp Loi l L mactanh L thi L in Thnh phn ha hc (%) CaF2 85 85 85 SiO2 5 5 4 CaO < 5 S< 0,2 0,2 0,2 m (%) 0,5 C cc (mm) 2050 550 550
Sa thch: thnh phn chnh l SiO2, bng 2.13 nu thnh phn mt s loi sa thch hay dng to x trong luyn thp nc ta. Bng 2.13 Thnh phn mt s loi sa thch dng to x khi luyn thp a danh khai thc Thi Nguyn Tnh Gia Ph Cm Ngh An 2.1.4. Cht tng cacbon tng hm lng cacbon trong thp ngi ta s dng: vn than cc, vn in cc hoc rt thm gang lng vo. Yu cu i vi mt s loi cht tng cacbon cho bng 2.14. Bng 2.14 Yu cu i vi mt s loi cht tng cacbon dng khi luyn thp Vt liu Vn than Vn in cc Thnh phnha hc (%) C 95 80 S< 0,1 0,1 tro (%) 2 15 m (%) 0,5 0,5 ht (%) 0,51,0 0,51,0 Thnh phn ha hc (%) Fe 1 1,2 1,8 S 0,08 SiO2 93 88 93 Al2O3 4 10 4 CaO 0,2 0,1 0,7 MgO 0,1 0,2 0,1
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2.1.5. Vt liu chu la Trong luyn thp, xy l v cc thit b lm vic nhit cao, ngoi cc vt liu thng dng nh st thp, btng ... ngi ta thng s dng mt lng ln gch chu la, gch cch nhit v cc vt liu chu la dng bt. Di y gii thiu mt s loi vt phm chu la thng dng dng trong xy dng thit b luyn thp. a) Vt phm inat: l vt phm chu la cha khong cht thch anh SiO2 >93%. + chu nng t 1690 1710oC; + Nhit bin mm di ti trng 2 kG/cm2 l 1650oC; + Bn vi mi trng axit; + Gin n nhit ln; + bn nhit thp. b) Vt phm samt: l vt phm chu la cha t 30 45 % Al2O3. + chu nng 1610 1730oC; + C tnh axit yu; + bn nhit tng i ln (10 50 ln); + Gin n nhit ln. c) Vt phm alumin cao: l vt phm chu la c hm lng Al2O3 t 46 100%. + chu nng cao v ph thuc hm lng Al2O3; + Bn vi c mi trng kim v mi trng axit; + bn c v bn nhit cao (trn 100 ln). d) Vt phm bn axit: l vt phm chu la cha 15 30 % Al2O3 v > 65 % SiO2. + chu nng 1610 1700oC; + Bn vi mi trng axit; + Bn nhit thp. e) Vt phm manhdit: l vt phm chu la cha 90 96 % MgO. + chu nng cao, trn 2000oC; - 16 -
+ Bn vi mi trng kim; + Bn nhit thp; + Gin n nhit ln; + Gim cht lng mnh khi b m. f) Vt phm crmit: l vt phm chu la cha 80 90 % crmit, 10 12 % manhdit v 7 10 % dumit. + chu nng 1900oC; + C tnh trung ho, bn vi c mi trng axit v mi trng kim; + Bn nhit thp (3 5 ln). g) Vt phm crmit - ma nhdit: l vt phm chu la cha 30 70 % crmit v 70 30 % manhdit. Tnh cht tng t manhdit nhng cht lng cao hn. h) Vt phm cacbon: Gm cc loi: cacbrun, graphit, cacbon. Vt phm cacbrun: vt phm sn xut t bt SiC c cht dnh kt l t st chu la v silicat st. + chu nng cao, trn 2000oC; + bn nhit cao; + Tnh chng mi mn v bn c hc tt; + Dn in, dn nhit tt; + Khi nhit trn 1300oC d b oxy ha v b kim n mn. Vt phm graphit: c sn xut t hn hp 20 60 % graphit, 30 40 % t st chu la v 10 40 % bt samt. + chu nng > 2000oC; + bn nhit tt; + H s gin n nhit nh; + Dn nhit tt; + Bn vi mi trng x v kim loi lng. Vt phm cacbon: thnh phn ch yu l cac bon, cha 80 90 %C. + chu nng cao > 2500oC; - 17 -
+ bn nhit tt; + Dn in v dn nhit tt; + H s gin n nhit nh. i) Vt liu cch nhit: Vt liu cch nhit dng trong l luyn thp gm hai nhm: + Vt liu cch nhit thin nhin: iatmit, inphurit, aming. + Vt liu cch nhit nhn to: vt phm chu la nh, x bng ... Diatmit, inphurit c thnh phn ch yu l SiO2 nhng c xp rt ln do dn nhit km, h s dn nhit 0,014 0,06 W/m.. Aming c thnh phn chnh l silicat manh ngm nc, h s dn nhit khong 0,15 W/m.. Vt phm chu la nh c thnh phn tng t cc vt phm chu la cng loi nhng c xp ln ( 50 80 %), do khi lng th tch b (0,27 1,3 kg/m3) v dn nhit km, h s dn nhit 0,11 0,81 W/m.. chu nng ca vt phm cch nhit thp hn chu nng ca vt phm chu la cng loi. X bng c sn xut t x luyn kim dng si, c xp ln, cch nhit v chu nng tt. j) Cc th gch xy xy cc thit b luyn thp, ngi ta s dng cc th gch chu la v cch nhit sn xut theo hnh dng v kch thc tiu chun ha. Trn hnh 2.1 gii thiu mt s th gch xy thng dng. Gch thng: dng xy tng thng, y l hoc phi hp vi gch vt xy vm v tng cong, kch thc ph bin l 230x113x65. Gch vt nm: dng xy tng cong hoc vm l c chiu dy mng, kch thc ph bin l 230x113x65/55 hoc 230x113x65/45 Gch vt ng: dng xy tng cong hoc vm l c chiu dy ln, kch thc ph bin l 230x113x65/55 hoc 230x113x65/45. Gch chn vm: dng xy chn vm cong, kch thc ph bin l 230x113x135/56/37.
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Gch vm treo: dng xy vm l phng bng mc treo, kch thc ph bin l 300x276x260/100/75/30.
c c a a b b d a d b c
a)
d a b
b)
c e
c)
f
c b
a d
c b d
d)
e)
g)
Hnh 2.1 Hnh dng v kch thc mt s loi gch quy chun a) Gch thng b) Gch vt nm c) Gch vt ng d) Gch chn vm e) Gch vm cu g) Gch vm treo
Khi chn gch xy l nn dng cc loi gch tiu chun c ch to hng lot v d kim. Trong trng hp cn dng cc loi gch phi tiu chun cng nn a v gn vi dng gch tiu chun vic ch to d dng hn. 2.2. Tnh ton thnh phn phi liu khi c thp Vic tnh ton thnh phn phi liu khi luyn thp ph thuc rt ln vo thit b nu v cng ngh nu luyn i vi l thi, vn cn gii quyt l m bo thnh phn, nhit gang lng a vo l v qu trnh cng ngh thi luyn, do vic tnh ton phi liu ch yu l tnh ton thnh phn phi liu khi nu gang lng theo yu cu ca l chuyn.
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i vi l Mactanh, l in h quang vic tnh ton phi liu ch yu l tnh ton thnh phn kim loi trong phi liu. Cc bc tnh ton theo trnh t sau: + Chn phng php nu: c hai phng php nu l nu khng c giai on oxy ha v nu c giai on oxy ha. Vic la chn phng php nu cn c vo ngun nguyn vt liu nu v c im ca thp cn nu. Chn phng php nu khng c giai on oxy ha khi yu cu cht lng thp khng cao, kh P v S khng trit , nguyn vt liu ch yu l vn thp ph. Chn phng php nu c giai on oxy ha khi yu cu cht lng thp cao (lng vt ln phi kim trong thp nh, kh P v S trit ), ngun nguyn vt liu c nhiu gang. + Tnh ton thnh phn nguyn liu kim loi: cn c tnh ton l thnh phn nguyn vt liu s dng, lng chy hao cc nguyn t trong qu trnh nu luyn v thnh phn mc thp cn nu. T l chy hao cc nguyn t khi nu trong l in h quang baz cho bng 2.15. Bng 2.15 T l chy hao cc nguyn t khi nu trong l in h quang baz Nguyn t Fe Mn Si Cr P S Lng chy hao trong cc giai on (%) Nu chy 25 50 70 50 75 10 5 50 60 Oxy ha 8 10 10 15 80 - 50 10 20 30 40 15 20 Hon nguyn 15 20 32 75 80
Thnh phn mc thp cn nu tra theo cc s tay. Khi tnh ton phi liu ch yu cn c vo thnh phn cacbon, cc nguyn t khc tnh sau khi tnh xong thnh phn phi liu, da vo s chy hao ca chng trong tng giai on m iu chnh vo cui giai on hon nguyn (i vi Mn, Si... ) hoc
- 20 -
tm cch kh cc giai on (i vi P, S). Thng tnh ton thnh phn phi liu theo %C sau khi nu chy xong. i vi phng php nu khng c giai on oxy ha, ta tnh ton sao cho khi nu chy xong %C nh hn gii hn dc ca mc thp cn nu. i vi phng php nu c giai on oxy ha, ta tnh ton sao cho khi nu chy xong %C phi ln hn gii hn dc ca mc thp cn nu khong 0,3 0,4 % . Trong trng hp nu thp cc bon cao th gim lng cc bon thp hn bnh thng mt t d dng cho vic kh P. Hm lng cacbon trong thnh phn phi liu bng tng lng cacbon trong gang, thp vn, phoi thp, hi liu. Khi tnh ton thnh phn phi liu c th dng phng php gii tch hoc phng php chn. Khi dng phng php gii tch, dng h phng trnh bc nht tnh ton. Cc phng trnh c lp da trn c s s nguyn t c chn lm cn c tnh ton v tng lng m liu. Gi s chn hai nguyn t tnh ton th s phng trnh lp c l ba phng trnh, do ch c chn ba n s l t l thnh phn ca ba loi liu. Nu s loi vt liu ln hn ba th chn trc t l dng mt s loi. Sau khi gii h phng trnh bc nht, xc nh c t l cc thnh phn, tin hnh kim tra hm lng cc nguyn t khc theo hm lng c trong m liu, tnh ton lng cn kh hoc a thm vo trong giai on oxy ha hoc giai on hon nguyn t c hm lng yu cu. Trong thc t luyn thp ngi ta hay dng phng php tnh ton thnh phn phi liu theo phng php chn. Cn c vo tnh hnh nguyn vt liu sn c v kinh nghim nu luyn, chn trc thnh phn m liu, thng ngi ta chn nh sau: i vi thp cacbon, chn: + + + + + St thp vn (ro cn, ro rn dp, ro tn dy, ..) : 46 50 %; Phoi thp (phoi tin, ro tn mng, ro vn ...) Gang luyn thp (hoc gang c) t P v S St thp vn : 70 90 %; :15 30%; : 35 20 %;
Hoc: Gang luyn P v S trung bnh : 35 20 %; - 21 -
i vi thp hp kim, chn: + + + + + St thp vn : 70 90 %;
Gang t P v S : 10 %; St thp vn : 20 %;
Hoc: Ph phm thp hp kim: 60 70%; Ph phm thp cc bon : 10 20%;
Sau khi chn xong thnh phn phi liu kim loi, ta tnh c thnh phn cc nguyn t (C, Si, Mn, P, S ...) trong phi liu, c bit l cacbon. Cc nguyn t ny thng cao hn yu cu. Nu lng cacbon qu cao c th tng t l thp vn, gim t l gang v tnh ton li. Qu trnh kh C, Si, Mn v P ch yu bng oxyt st do m liu a vo, do thp b oxy ha, hoc do oxyt st a vo trong giai on oxy ha. + Tnh ton lng qung cn thit t chy C v cc tp cht: khi nu c giai on oxy ha cn xc nh lng qung st a vo lm cht oxy ha. Trong qung st ngoi oxyt st Fe2O3 l ch yu, cn cha mt lng nh Fe3O4, FeO v cc tp cht. Khi tnh ton ngi ta quy i F3O4 v FeO v Fe2O3, do thnh phn qung tnh ton ch cha Fe2O3 v tp cht. Khi a qung st vo l s xy ra phn ng:
Fe 2 O 3 + Fe 3FeO Khi s xy ra phn ng t chy cc tp cht v cacbon:

Si + 2FeO SiO 2 + 2Fe
Mn + FeO MnO + Fe 2P + 5FeO P2 O 5 + 5Fe
C + FeO Fe + CO
Da vo lng oxy cn thit cho tng phn ng v lng cc nguyn t cn kh ta tnh c lng oxy cn thit v tnh ra lng qung cn dng. + Tnh ton lng cc nguyn liu khc a vo l: m bo tnh cht ca x, kh c P, S v oxy ... ta cn tnh ton lng cht to x, cht kh oxy a vo
- 22 -
l. Mun tnh lng cht kh oxy cn dng, ta cn phi bit lng oxyt st cn li sau giai on oxy ha, s phn b ca n trong x v kim loi, phng php kh v loi cht kh a vo, lng nguyn t cn iu chnh... , do qu trnh tnh ton thng phc tp v d sai st. Trong thc t, n gin ngi ta thng tnh ton gn ng nh sau: i vi cht to x, tnh theo trng lng phi liu kim loi: Cht to x vi: 2 3% ; Samt: 0,2 0,15%; Hunh thch: 0,13%; i vi cht kh v iu chnh thnh phn, tnh theo trng lng kim loi lng: Nhm: 0,5 1,5 kg/tn; Siliccanxi hay silicmangan: 0,5 1 kg/tn; Fermangan: 13 15 kg/tn; Ferersilic: 7,5 10 kg/tn.
- 23 -
Chng III L THUYT QU TRNH LUYN THP

Qu trnh luyn thp xy ra trong iu kin nhit cao, l kt qu ca nhiu qu trnh tc dng ha l phc tp gia kim loi, x, mi trng kh l, nhin liu, vt liu xy l ... trong qu trnh oxy ha v hon nguyn cc nguyn t ng mt vai tr ht sc quan trng. Trong chng ny nghin cu mt s vn c bn lin quan n cc qu trnh luyn kim trong luyn thp. 3.1. L thuyt v s oxy ha v hon nguyn Trong qu trnh luyn thp, phn ng oxy ha - hon nguyn ph bin l theo h oxy. Phng trnh tng qut ca phn ng c dng sau:
2Me + O 2
Me + XO 2MeO MeO + X
(3.1) (3.2)
Trong : Me - nguyn t oxy ha; X - nguyn t hon nguyn. V d qu trnh hon nguyn st xy ra theo phn ng:
Fe 2 O 3 + 3C Fe + 3CO + Q
Tt c phn ng trong luyn thp u xy ra th lng, trong Fe ng vai tr dung mi, cc cht khc l cht tan. c trng cho kh nng xy ra phn ng oxy ha - hon nguyn, ngi ta thng xt gi tr thay i nng lng t do ca h thng Z. Trong iu kin tiu chun th:
Z 0 = H 0 TS0 = 4,575T lg K p T T T
(3.3) (3.4)
Do : Trong :
H 0 S0 T T lg K p = + 4,575T 4,575
Z 0 - s thay i nng lng t do ca h thng; T H 0 - s thay i nhit hm ca h thng (entanpi). T
- 24 -
S0 - s thay i entrpi ca h thng; T
T - nhit tuyt i; Kp - hng s cn bng; mi nhit , trong h thng kim loi - oxy - oxyt u c p sut ring phn ca oxy tng ng trn kim loi v oxyt. p sut ring phn ( PO ) ca oxy trong pha
2
kh khi n cn bng vi oxyt v kim loi th gi l p sut phn ly ca oxyt v ta c:

K p = PO
2
p sut phn ly oxyt cng nh th nguyn t kim loi cng d b oxy ha. Bnh thng, p sut ring phn ca oxy trong pha kh thng ln hn p sut phn ly ca cc oxyt kim loi nn hu ht kim loi u b oxy ha. Khi tng nhit , p sut phn ly ca oxyt tng rt nhanh, nn phn ng oxy ha ca nhiu nguyn t kim loi gim. thy r kh nng oxy ha ca mt s kim loi thng thy trong qu trnh luyn thp ta kho st H 0 v Z 0 ca mt s phn ng thng gp. T T Bng 3.1 Gi tr ca H 0 v Z 0 ca mt s phn ng thng gp T T
Phn ng ha hc to ra oxyt
2Ca + O 2 = 2CaO
Z 0 kj/mol O2 298 1000oC - 1068 1600oC - 942,11
H0 298 kj/mol O2 - 1270,27
4 2 Al + O 2 = Al 2 O 3 3 3
Si + O 2 = SiO 2
- 895,75 - 690,28
- 781,47 - 581,17
- 497,78 - 872,99
2Mn + O 2 = 2MnO
2Fe + O 2 = 2FeO 2 Ni + O 2 = 2 NiO
-624,67 - 399,10 - 306,27 -190,92
- 535,91 - 313,13 -190,54 - 103,84
- 779,58 - 540,10 - 339,24 - 339,24
Cu + O 2 = CuO 2
T bng (3.1) v cc phng trnh trn ta c nhn xt: thng Z 0 < 0 , do T cc phn ng t xy ra theo theo chiu oxy ha. Phn ng oxy ha no c Z 0 m T
- 25 -
cng ln th phn ng tin hnh cng mnh. Do nguyn t no xp trn st (c Z 0 T nh hn) th s b oxy ha, cn cc nguyn t xp di st (c Z 0 ln hn) th thc T t kh b oxy ha. phng trnh phn ng (3.2), phn ng ch xy ra theo chiu thun khi
Z 0 < Z 0 , nu Z 0 > Z 0 phn ng s xy ra theo chiu ngc li. MeO XO MeO XO
Mt khc, H 0 = Q p , trong Qp l nhit phn ng, theo bng (3.1) th ni T chung cc phn ng c H 0 < 0 , do Q p > 0 tc l phn ng ta nhit. V vy, khi T nhit ca h thng tng ln th Kp gim i, c ngha l phn ng tin dn ti cn bng v chuyn sang chiu ngc li (hon nguyn). Trn thc t, trong khong nhit nu luyn, tr s ca H 0 v ST thay i t chng t phn ng hon nguyn xy ra T yu hoc kh xy ra. Tc oxy ha cc nguyn t bn cnh ph thuc vo i lc ha hc ca nguyn t vi oxy cn ph thuc nng , do khi cp oxy vo l st thng b oxy ha ngay mc d i lc ca n vi oxy nh hn Si, Mn. phn ng xy ra th Z < 0 , do kh c cc tp cht khi st th
G ca chng phi nh hn so vi st.
3.2. S oxy ha v hon nguyn cc nguyn t 3.2.1. S oxy ha v hon nguyn st
St trong phi liu luyn thp chim ti 90 96%, do mc du i lc ha hc ca st vi oxy thua mt s nguyn t khc (nh Mn, Si ...) nhng trong qu trnh nu luyn phn ng oxy ha st thng xy ra trc, sau oxyt st li l ngun cung cp oxy oxy ha cc tp cht khc. S chuyn bin ca h Fe - O thng theo hai h thng: + Fe - FeO - Fe3O4 - Fe2O3 ( vng nhit > 570oC). + Fe - Fe3O4 - Fe2O3 ( vng nhit < 570oC). Ty thuc phng php cp oxy m c cu ca phn ng oxy ha st tin hnh c th khc nhau. Thc t, ngi ta cung cp oxy cho qu trnh nu luyn theo ba phng php: - 26 -
+ Trc tip thi oxy vo l; + a qung st vo l; + Nh mi trng kh l. Khi thi trc tip oxy (hay khng kh) vo thp lng, c cu phn ng xy ra nh sau:
{O 2 } = 2[O]
(3.5) (3.6) (3.7)
[Fe] + [O] = FeO xFeO = y[FeO] + z(FeO )

Vi
x = y+z
Fe 2 O 3 qung (Fe 2 O 3 )
Khi a trc tip qung vo hp kim lng:
(3.8) (3.9) (3.10)
x (Fe 2 O 3 ) + x[Fe] 3x.FeO

3x.FeO = 3y[FeO] + 3z(FeO )
Vi
x = y+z
Khi cung cp oxy bng mi trng kh l: nu trong mi trng kh l c cha cc kh oxy ha (hi nc, CO2, O2 ...) th kh ny s truyn oxy cho st qua x, qu trnh c th m t nh sau: + b mt tip xc gia x v kh: 2(FeO) + 1 {O 2 } = (Fe 2 O 3 ) 2 (3.11)
+ (Fe 2 O 3 ) khuch tn qua x n b mt tip xc gia x v kim loi v xy ra phn ng:

x (Fe 2 O 3 ) + x[Fe] 3xFeO
(3.12) (3.13)
3x.FeO = 3y[FeO] + 3z(FeO) Vi

x = y+z
Mun qu trnh ny tin hnh nhanh th mi trng phi l mi trng kh oxy ha, x cha nhiu FeO v c tnh linh ng tt.
- 27 -
Phn ng oxy ha st l phn ng ta nhit nn khi nhit tng tc phn ng s chm li. Phn ng hon nguyn st trn thc t rt kh xy ra, trong nu luyn hon nguyn st ngi ta a vo hp kim lng cc nguyn t c i lc ha hc vi oxy mnh hn st. Cc nguyn t ny c th a vo trong kim loi (Mn, Si, Al ...) hoc ri ln x (bt cc, bt fersilic)
3.2.2. S oxy ha v hon nguyn mangan
Mn l nguyn t hp kim nh hng ln n c tnh ca thp. Mn lm tng bn, cng ca thp, tng tnh chu mi mn. Tuy nhin hm lng Mn phi nm trong mt phm vi nht nh, khi vt qu gii hn nht nh li c nh hng c hi. Theo bng (3.1), phn ng oxy ha Mn c Z nh hn phn ng oxy ha st, do khi nu luyn Mn d b oxy ha. Khi thi oxy trc tip vo kim loi lng th xy ra phn ng:
[Mn ] + 1 {O } = (MnO )
2
2
(3.14)
Khi trong kim loi lng cha [FeO] hay kh oxy trc tip bng Mn th:
[Mn ] + [FeO] = (MnO ) + [Fe]

Khi trong x cha nhiu FeO th phn ng xy ra in hnh l:
(3.15) (3.16)
[Mn ] + (FeO) = (MnO ) + [Fe]

Phn ng c:
Z = 30.200 + 14,4T
Hng s cn bng:
K Mn = N (FeO ) .[% Mn ] 6.600 3,16 T 1 N ( MnO ) . K Mn N ( FeO ) N (MnO )
(3.17) (3.18)
V Suy ra:
lg K Mn =
[%Mn ] =
(3.19)
- 28 -
Khi t s
N ( MnO ) N ( FeO )
khng i, nu tng nhit th lng Mn cn li trong kim
loi tng (do KMn gim), ngc li khi nhit khng i ( K Mn = const ), vi cng t s
N ( MnO ) N ( FeO ) th [% Mn ] di x baz cao hn di x axit. V vy, qu trnh l axit th
Mn b oxy ha hon ton hn qu trnh l baz. Do phn ng oxy ha Mn l phn ng ta nhit, nn khi nhit tng tc phn ng s chm li. Khi nhit rt cao, c th xy ra s hon nguyn Mn, qu trnh ny thng km theo s oxy ha cacbon, do ta c th coi n l kt qu ca hai phn ng ng thi:
(MnO ) + [Fe] = [Mn ] + (FeO ) (FeO) + [C] = {CO} + [Fe] (MnO ) + [C] = [Mn ] + {CO}
(3.20) (3.21) (3.22)
Trong thc t nu luyn rt kh xy ra phn ng hon nguyn Mn trc tip bng cacbon, nhng trong l axit Mn c th c hon nguyn bi Si:
2(MnO) ) + [Si ] = (SiO 2 ) + 2[Mn ]
(3.23)
Trong luyn thp ngi ta thng s dng Mn t c mc ch: + m bo c tnh cho thp c; + Kh oxy s b cho nc thp. Kh nng kh oxy ca Mn rt yu nhng ngi ta vn dng Mn kh oxy s b nhm gim hm lng oxy trong thp trc khi kh bng Si v Al, mt khc khi cho Mn vo thp cho php ta iu chnh s si ca thp trong khun, khi thp ng c Mn ngn cho thp khng b oxy ha tip bi kh tri, trnh c hin tng si khun.
3.2.3. S oxy ha v hon nguyn silic

Si cng l mt nguyn t hp kim nh hng ln n c tnh ca thp. Si tng kh nng chng r, i vi mt s thp Si c tc dng tng t tnh. Cng nh Mn, hm
- 29 -
lng Si trong thp phi nm trong mt phm vi nht nh, khi vt qu gii hn cn thit li c nh hng c hi. Phn ng oxy ha Si xy ra c khi nu chy, trong giai on oxy ha to thnh
(SiO 2 ) hoc (SiO ) v h Si - O chuyn bin theo hai h thng:

Si Si
SiO
siO2 ( nhit > 1500oC) siO2 ( nhit < 1500oC)
Phn ng oxy ha Si cng ph thuc phng php cp oxy. Nu thi oxy trc tip vo thp lng:
2[Si ] + {O 2 } = 2(SiO )
(3.24) (3.25)
Hay
[Si] + {O } = (SiO )
2 2
Khi kh oxy bng Si hay trong thp c nhiu [FeO] th xy ra phn ng:
[Si] + 2[FeO] = (SiO ) + 2[Fe]

2
(3.26)
in hnh nht l phn ng khc pha xy ra mt phn cch gia x v kim loi:
[Si] + 2(FeO) = (SiO ) + 2[Fe]

2
(3.27) (3.28)
Phn ng c:
Z = 87.000 + 50,7T
K Si =
[%Si].N
N (SiO
2 ( FeO )
(3.29)
lg K Si = T (3.29) suy ra:
19.057 11,1 T 1 N (SiO ) . K Si N (2FeO )

2
(3.30)
[%Si] =
(3.31)
Phn ng (3.27) cn ph thuc vo tng quan gia p sut phn ly oxyt ca oxyt silic v oxyt st. giai on u nu chy, PO
2 ( FeO )
> PO
2 ( SiO 2 )
nn Si b oxy ha,
nhng cui giai on nu chy (l mctanh, l thi) th s khc nhau gia chng khng ln lm do phn ng dn t ti trng thi cn bng.
- 30 -
T cc phn ng trn ta nhn thy phn ng oxy ha Si l phn ng ta nhit, do khi nhit tng, tc phn ng chm li v c th dn ti t cn bng hoc chuyn sang hon nguyn Si. Kh nng t cn bng hoc chuyn sang hon nguyn Si ph thuc qu trnh luyn. Trong l baz, u giai on nu, mt phn (SiO 2 ) to ra s lin kt vi
(FeO) v to thnh hp cht phaialit: (SiO 2 ) + 2(FeO) = (Fe 2SiO 4 )

tch dn ra:
(3.32)
V sau, ty thuc theo mc ha tan ca vi trong phaialit m oxyt st s
(Fe 2SiO 4 ) + 2(CaO ) = (Ca 2SiO 4 ) + 2(FeO)
(3.33)
Nh vy trong x baz, oxyt silic nm dng silicat v phn ng (3.27) ch t cn bng khi nng Si trong thp rt thp, do phn ng hon nguyn Si rt t kh nng xy ra. Trong l in h quang, i khi c s hon nguyn Si ti 0,1 0,15% vo giai on kh oxy khuch tn. Trong l in axit, do x bo ha (SiO2) v rt t oxyt st t do, do cui giai on nu, Si b hon nguyn kh nhiu bng C v Fe. Trong nu luyn thp, Si c s dng nhm mc ch: + m bo thnh phn ha hc ca hp kim, t c c tnh v cc tnh cht khc theo yu cu; + Kh oxy cho nc thp. Trong l in baz ngi ta cho trc tip fersilic vo nc thp kh oxy theo phn ng:
[Si] + 2[FeO] = (SiO ) + 2[Fe]

2 ' K Si =
(3.34)
[%Si][FeO] .
N (SiO
' lg K Si =
26.050 + 10,85 T
- 31 -
Trong l in axit do nng oxyt st trong x nh, oxyt silic b bo ha v p sut phn ly ca oxyt cacbon nh hn p sut phn ly ca oxyt silic, do Si c hon nguyn nhiu bi Fe v C:
(SiO 2 ) + 2[C] = [Si] + 2{CO} (SiO 2 ) + 2[Fe] = [Si] + 2(FeO)
(3.35) (3.36)
Si hon nguyn t cc phn ng (3.35) v (3.36) c th dng kh oxy theo phn ng (3.34). Trong trng hp cn kh oxy nhanh ngi ta cng c th cho thm fersilic vo thp lng. V kh nng kh oxy, th Si kh oxy mnh hn Mn, khi nhit tng kh nng kh oxy ca Si gim.
3.2.4. S oxy ha ca cacbon
Hm lng cacbon trong thp ph thuc vo mc thp, nhim v ca luyn thp l kh bt C khi d v b sung C khi thiu. Ring i vi thp khng r, khi luyn phi kh C xung hm lng thp nht c th. Phn ng oxy ha cacbon l phn ng ch yu trong qu trnh luyn thp v c nh hng rt ln n thi gian nu luyn. Tc oxy ha cacbon ph thuc hai qu trnh ch yu: + Qu trnh cung cp oxy; + Phn ng oxy ha cacbon. Khi thi oxy trc tip vo thp lng (trong l chuyn) th phn ng oxy ha cacbon xy ra nh sau:
[C] + 1 {O } = {CO}
2
2
(3.37)
Hoc theo h hai phng trnh c phn ng trung gian:
[Fe] + 1 {O } = [FeO]
2
2
[FeO] + [C] = [Fe] + [CO] [CO] = {CO}
(3.38)
- 32 -
1 {O 2 } + [C] = {CO} 2 ng oxy ha cacbon s xy ra theo nhiu giai on: + Khuch tn oxyt st t x vo kim loi:
(3.39)
Khi cung cp oxy t kh l qua x hoc oxy t x ni chung, th c cu ca phn
(FeO) [FeO]
+ Khuch tn cacbon vo khu vc phn ng: + Phn ng gia [FeO] v [C]:
[FeO] + [C] = [Fe] + [CO] + To kh {CO} : [CO] = {CO}

Do , phn ng chung s l:
(3.40)
(FeO) + [C] = [Fe] + {CO}
(3.41)
Trong cc phn ng trn, thc t do CO khng ha tan trong thp lng, cc phn ng (3.38) v (3.40) khng pht trin nhiu c m ch yu ch xy ra trn b mt cc bt kh theo phn ng khc pha. Trong l thi, qu trnh s xy ra trm mt cc bt khi do gi thi vo v cc bt kh CO mi to thnh. Trong l mactanh, l in th lc u phn ng pht trin t cc tm mm kh trn cc mt nhm ca tng l, y l, liu ... sau cc phn ng tip tc pht trin t cc bt kh CO va mi to thnh. Thc t xc nhn rng: s hn ch qu trnh oxy ha cacbon khi cung cp oxy t x khng phi do phn ng ha hc m ch yu do qu trnh khuch tn. Xt trng hp l mactanh, quan h gia hm lng [FeO] v [C] trong kim loi c dng nh hnh 3.1. Qua th nhn ta thy vi p sut phn ly PCO = 1 atm v nhit 1600oC th tch s %C.%FeO = 0,0112 cao hn nhiu so vi l thuyt. S d c s chnh lch ny l do s khuch tn xy ra vi tc rt chm, nht l qu trnh khuch tn
(FeO) [FeO] .
- 33 -
%FeO 0,5 3 0,4 0,3 0,2 2 0,1 1 0 0,1 0,2 0,3 0, 0,5 0,6 0,7 0, 0,9 %C
Hnh 3.1 Quan h cn bng ca [FeO] v [C] trong l mactanh p sut PCO = 1,0 1,5 atm 1) Cn bng 2) trong l 3) lp kim loi st di x
Trong qu trnh luyn thp, do cacbon b oxy ha sau khi oxy ha gn ht Si, phn ln Mn v cc nguyn t c i lc ha hc vi oxy mnh hn cacbon. V vy, khi luyn thp c giai on oxy ha, khng nn a cc nguyn t hp kim d b oxy ha vo trc giai on oxy ha, nu khng s lm tn hao nguyn t hp kim v hn ch tc oxy ha cacbon. Tc oxy ha cacbon ch yu do qu trnh cung cp oxy (phng php cung cp v s khuch tn ca oxy trong kim loi). Chnh v vy, tc oxy ha cacbon trong cc l thng rt khc nhau, trong l thi tc oxy ha cacbon t ti 0,5%/pht, trong khi trong l mactanh ch khong 0,002 0,007%C/pht. Tc khuch tn v thot kh CO ph thuc rt ln vo st ca x v chiu dy lp x. X long v chiu dy mng th tc khuch tn v thot kh nhanh.. Khi nu luyn thp, nhn vo s ni ca bt kh c th d on c chiu dy ca lp x, khi chiu dy lp x hp l, bt kh ch hi n trn mt lp x v khng nhn thy mt thong nc thp.
3.2.5. Kh phtpho
Phtpho l nguyn t c hi trong thp v n lm gim tnh do ca thp, gy ra hin tng dn ngui, c bit l khi hm lng cacbon trong thp cao. Ch trong mt - 34 -
s mc thp, khi yu cu b mt gia cng cn nhn cao hoc cn phoi d gy vn to thun li cho qu trnh gia cng, mi dng thp c hm lng P cao. Trong qu trnh luyn thp, s oxy ha P xy ra theo phn ng:
2[P ] + 5(FeO) = [P2 O 5 ] + 5[Fe] + Q
2 5
(3.42)
2 5
[P O ] khuch tn vo x kt hp vi (FeO) to thnh mui (3FeO.P O )

ng:
theo phn
(P2 O 5 ) + 3(FeO) = (3FeO.P2 O 5 )

Mui (3FeO.P2 O 5 ) rt khng n nh khi nhit cao v mi trng x axit. Khi c mt (SiO 2 ) , mui (3FeO.P2 O 5 ) tc dng vi (SiO 2 ) theo phn ng:
(3FeO.P2 O 5 ) + 3(SiO 2 ) = (3FeO.SiO 2 ) + (P2 O 5 ) (P2 O 5 ) tc dng vi [C] v hon nguyn P tr li kim loi:
(P2 O 5 ) + 5[C] = 2[P] + 5{CO}

Nh vy, trong qu trnh axit khng c kh nng kh P. Trong trng hp ny, luyn c thp tt phi s dng nguyn liu cha t P. Trong mi trng x baz, x cha nhiu (CaO ) , nn (P2 O 5 ) tc dng vi
(CaO ) theo phn ng: (P2 O 5 ) + 3(CaO) = (3CaO.P2 O 5 )

Hoc
(3.43) (3.44)
(P2 O 5 ) + 4(CaO ) = (4CaO.P2 O 5 )
V (3CaO.P2 O 5 ) hoc (4CaO.P2 O 5 ) l cc phc cht khng b phn hy nhit cao nn cc phn ng trn xy ra theo chiu oxy ha P. Phng trnh phn ng chung c dng: 2[P ] + 5(FeO) + 3(CaO ) = (3CaO.P2 O 5 ) + 5[Fe] + Q T phng trnh (3.45), ta nhn thy iu kin kh P tt l: + kim ca x B = (3.45)
(CaO) (SiO 2 )
phi cao, ng thi trong x phi cha nhiu
(FeO) ;
+ Nhit l thp, tt nht l trong khong 1300 1350oC;
- 35 -
+ Din tch tip xc gia thp lng v x phi ln (do phn ng xy ra gia hai pha). Trong thc t, khi nu thp trong l mactanh hoc l in h quang baz ngi ta tin hnh kh P vo cui giai on nu chy v u giai on oxy ha v l thi k c iu kin kh P tt nht do nhit l cn thp, nng oxyt st kh cao c th nng baz ca x ti 2,5 3. Trong l thi baz, ngi ta thng tin hnh kh P vo giai on gia, khi thnh phn ca x cha khong: 6,4 9,4% SiO2; 2,9 9% Al2O3; 44,1 53,3% CaO; 36 12,4%MgO; 4,2 7,9%MnO; 15,0 23,93%FeO. Ngoi phng php kh P bng x ngi ta cn dng cc nguyn t kim loi nh Ca, Mg, RE (t him: cha Ce, La) kh P. Khi a cc kim loi trn vo thp lng, chng kt hp vi P to thnh cc hp hp cht bn nhit cao (CaP, MgP, (Ce + La)P ...) v i vo x. Mt vn cn lu l khi dng cc kim loi trn kh P, trc ht cn phi kh ht oxy v i lc ha hc vi oxy ca cc nguyn t ny ln hn rt nhiu so vi P.
3.2.6. Kh lu hunh
Lu hunh l tp cht c hi trong thp (gy ra hin tng b nng). Bi vy, thp c cht lng cng cao th hm lng S trong thp yu cu cng thp, i vi thp sch phi kh S hu nh trit . Lu hunh ho tan c vo Fe, nhit cng cao th ha tan cng ln, phng trnh kh S: [FeS] + [CaO] [CaS] + [FeO] - Q T phng trnh phn ng ta nhn thy iu kin kh S tt l: + CaO cao ( kim cao); + Nng (FeO) thp; + Nhit cao. Qu trnh kh S c th tin hnh bng x, kh ho v kh lng. Khi kh S qua x, do FeS ha tan c trong x v kim loi, hng s phn b: (3.46)
- 36 -
K FeS =
[%FeS]
N (FeS)
mt iu kin nu luyn nht nh th KFeS l hng s, nu ta tm cch gim

N ( FeS) ti mc K FeS .[% FeS] > N (FeS) th [FeS] (FeS) . gim N ( FeS) ngi ta thng
dng cc bin php chuyn (FeS) t dng d ha tan sang dng kh ha tan nh cc phn ng:
(FeS) + (MnO ) = (MnS) + (FeO) (FeS) + (CaO) = (CaS) + (FeO)

S cao, phng php kh li n gin v rt kinh t.
(3.47) (3.48)
Ngi ta thng kh S theo phn ng (3.48), v phn ng ny c hiu qu kh Trong cc l luyn thp, ngi ta thng kh S vo lc nhit nc thp cao, nng (FeO ) thp v nng baz n 2,8 3,2. V d, trong l in h quang baz, ngi ta tin hnh kh S vo cui giai on oxy ha v ch yu vo u giai on hon nguyn. Khi kh S trong mi trng kh ha, S b t chy theo phn ng: S + O2 = SO2 (3.49) Khi kh lng, ngi ta a vo thp lng cc kim loi (chng hn nh: Ca, Mg, RE) d kt hp vi S to thnh cc hp cht bn. Khi kh S bng phng php ny, phi tin hnh kh ht oxy trong thp trc khi kh S.
3.2.7. Kh kh
Kh ho tan vo thp c ngun gc t nguyn vt liu, khng kh... chng c th lm gim c tnh ca thp, cng nh gy ra r kh khi c. Thng khi luyn thp cn tin hnh kh cc kh [O], [N], [H].
a) Kh oxy
Oxy c cp vo thp lng oxy ha cc nguyn t d tha nh C, Si, Mn... sau khi oxy ha cc tp cht trong thp cn mt lng oxy d. kh oxy c th tin hnh bng phng php kh lng hoc kh khuch tn.
- 37 -
Trong phng php kh lng ngi ta dng cc nguyn t kim loi c i lc vi oxy ln hn so vi st: [Mn] + [O] (MnO) [Si] + 2[O] (SiO2) [Al] + 3[O] (Al2O3) im l cc oxyt to thnh ni ln khng trit lm bn thp. Phng php kh khuch tn dng fero (fersilic, fermangan) cho vo thp lng hoc cacbon ht vo x. (FeO) + C = (Fe) + CO (FeO) + Si = (Fe) + (SiO2) (3.53) (3.54) (3.50) (3.51) (3.52)
Phng php kh lng c u im: tc phn ng nhanh nhng c nhc
Do hng s phn b oxyt st trong x v trong kim loi lng

Kp =
(FeO) = const , nn khi (FeO) gim ko theo [FeO] gim theo. Phng php kh [FeO]
lng khng lm bn nc thp nhng tc kh chm, ko di thi gian kh, do thng dng khi luyn thp yu cu sch cao. Ngoi ra i vi thp cht lng cao, ngi ta c th tin hnh kh oxy bng phng php chn khng.
b) Kh [N] v [H]:
N2 = 2[N] H2 = 2[H] Hng s phn ly:
Kp
(3.56) (3.57) [N ] = K p PN [H ] = K 'p PH

2
[N] =
PN
2
K 'p =
[H]
PH
2
Phng php kh ch yu l kh khuch tn, do trong qu trnh kh phi to nn s xo trn kim loi tt tng cng s ni ca bt kh. tng tc kh kh, ngi ta c th dng kh tr sc vo thp lng.
- 38 -
3.2.8. Tp cht phi kim

Tp cht phi kim l nhng cht ln khng ni ln c trong qu trnh luyn v nm li trong thp, chng ch yu l cc oxyt. Tp cht phi kim trong thp hnh thnh do ni sinh hoc t ngoi a vo. Tp cht ni sinh l sn phm ca s oxy ha, tp cht t ngoi a vo do nguyn vt liu ln cht bn, do vt liu chu la b n mn, do ln x v s ti oxy ha. Tp cht phi kim lm gim cht lng ca thp, do vy trong qu trnh nu luyn cn c bin php hn ch ngun tp cht a t ngoi vo, nh dng nguyn vt liu sch, s dng vt liu chu la ph hp gim s n mn, s dng cht kh ph hp v lng dng hp l, hn ch s ti oxy ha ... hoc dng cc bin php tinh luyn ngoi l.
3.3. X trong qu trnh luyn thp

Trong qu trnh nu luyn hp kim, d mun hay khng bao gi cng c mt lng tp cht t nhiu ngun khc nhau a vo l v tch ra trong qu trnh nu luyn to thnh x. Trong l, do x tip xc trc tip vi kim loi nn tc ng rt ln ti nhiu qu trnh ha l lin quan n tin trnh thc hin qu trnh cng ngh. Trong mt s qu trnh nu luyn (nh nu gang chng hn) qu trnh to x l qu trnh khng mong mun nhng trong luyn thp x li ng vai tr rt ln trong nhiu qu trnh luyn kim xy ra trong l nh qu trnh truyn nhit, qu trnh kh tp cht, kh kh ... Bi vy, ty thuc yu cu cng ngh, trong tng giai on nu ngi ta thng xuyn phi iu chnh ch x ph hp m bo cho qu trnh luyn pht trin theo hng cng ngh mong mun.
3.3.1. Ngun gc v thnh phn ca x luyn thp a) Ngun gc ca x

Khi lng v thnh phn ca x ph thuc vo phm cht ca nguyn, nhin vt liu nu, vt liu xy l v ch nu luyn. Trong qu trnh nu luyn, x c hnh thnh t cc ngun ch yu sau y: + Do cc cht ln trong nguyn, nhin vt liu (nh t ct, du m, nc...), do nguyn liu kim loi b oxy ha mang vo; + Do kim loi v tp cht trong phi liu b oxy ha; - 39 -
+ Do tng l b n mn: trong iu kin nhit cao, do tc dng c hc hoc s n mn ha hc, lp lm vic ca tng l b bo mn v i vo x. + Do cc oxyt v tp cht a vo cng cht oxy ha, v d khi a qung st vo oxy ha tp cht v cacbon, mt lng ln oxyt st v cc oxyt khc c a vo l. + Do cc tp cht ln trong cc cht to x; + Do tro ca nhin liu: trong nhin liu c bit l nhin liu rn thng cha mt lng tro nht nh, khi nu luyn mt phn cun theo kh l, mt phn nm li trong l v i vo x.
b) Thnh phn ha hc ca x
Thnh phn ch yu ca x luyn thp l cc oxyt, theo tnh cht ha hc ca chng c th chia lm ba nhm: nhm c tnh cht baz, nhm c tnh cht axit v nhm c tnh cht lng tnh. Nhm cc oxyt c tnh baoz gm: CaO, MgO, MnO, FeO, NiO, ... Nhm cc oxyt c tnh axit gm: SiO2, P2O5, TiO,V2O5, ... Nhm cc oxyt c tnh cht lng tnh gm: Al2O3, Fe2O3, Cr2O3, V2O3, ... Trong cc cc oxyt c tnh cht lng tnh, ch c Al2O3 l th hin tnh cht lng tnh r rt cn Fe2O3 v Cr2O3 thng mang tnh axit yu. Ngoi cc oxyt trn, trong x cn cha cc hp cht khc nh: CaS, FeS, CaS2... Cc oxyt trn khi dng t do phn ln c nhit chy rt cao, tuy nhin trong x ngoi cc oxyt t do, cn c cc hp cht ca nhiu oxyt vi nhau m thng c nhit chy gim mnh. Chnh v vy, trong iu kin nu luyn x thng trng thi lng. Cc hp cht thng gp trong x luyn thp c nhiu loi nhng c th chia thnh bn nhm chnh: Nhm silicat:
(FeO)x .SiO 2
MnO.SiO 2
(x = 1; 2)
(CaO )x .SiO 2
(x = 1; 2) - 40 -
MgO.SiO 2
Al 2 O 3 .SiO 2 .... Nhm phtphat:
(FeO)3 .P2 O 5
MnO.P2 O 5
(CaO )x .P2 O 5
(x = 3; 4)
(MgO )3 .P2 O 5 ...

Nhm aluminat:
FeO.Al 2 O 3 CaO.Al 2 O 3 MgO.Al 2 O 3 ...
Nhm pherit: FeO.Fe 2 O 3
(CaO )x .Fe 2 O 3
(CaO )x .(Fe 2 O 3 )y ...
(x = 1; 3)
Ngoi cc hp cht trn, x cn cha mt s hp cht phc tp khc nh:

CaO.MeO.SiO 2
(Me = Fe, Mn, Mg ...)
5CaO.P2 O 5 .SiO 2 ... Trong thnh phn ca x th cc oxyt t do quyt nh hot tnh ha hc ca x, cc hp cht nhiu oxyt lm nhit chy ca x gim thp, m bo cho x c st, chy long v mt s tnh cht khc cn thit theo yu cu cng ngh. Trong luyn thp, ngi ta c bit ch ba loi oxyt: (CaO ) , (SiO 2 ) v
(FeO) . Cc oxyt (CaO)

kh nng oxy ha ca x.
v (SiO 2 ) quyt nh baz ca x, cn (FeO) quyt nh
3.3.2. Cc tnh cht ca x luyn thp

a) baz ca x: baz ca x xc nh bi t s gia t l phn trm theo trng lng ( hoc t l phn t gam) ca hai oxyt (CaO ) v (SiO 2 ) : - 41 -
B=
(%CaO ) (%SiO 2 )
hoc B =
N (CaO ) N (SiO
2
(3.58)
Khi lng (P2 O 5 ) trong x cao, ngi ta tnh baz ca x theo cng thc sau: B' =
(%CaO ) (%SiO 2 ) + (%P2 O 5 )
hoc
B' =
(%CaO ) 1,18(%P2 O 5 ) (%SiO 2 )
Cn c vo baz ca x ngi ta chia ra: + X c baz thp : B = 1,3 1,5 (35 40 %CaO, 25 30 %SiO2);
+ X c baz trung bnh : B = 1,8 2,2 (40 45 %CaO, 20 25 %SiO2) + X c baz cao : B = 2,5 (45 48 %CaO, 12 20 %SiO2)
Trong l luyn thp axit, ngi ta cn dng axit thay cho baz, xc nh theo cng thc: R=
(%SiO 2 ) (%CaO )
baz ca x c ngha rt ln trong vic kh P, S v m bo cho nhiu tin trnh cng ngh tin hnh thun li. baz nh hng ln n chy long ca x, do nh hng ln n hot tnh ca x, kh nng ht kh hoc thot kh ca kim loi v kh nng kh tp cht. V vy, ty theo nhit trong l v yu cu cng ngh, khi nu luyn cn phi thng xuyn kim tra v iu chnh baz ca x.
b) Cc tnh cht vt l ca x
st ca x: c trng cho linh ng ca x, st cng cao th linh ng ca x cng thp. n v o st l poa (g/s), mt poa bng 100 ln st ca nc 20oC. Bng 3.2 cho st ca thp v x cc nhit nht nh. Bng 3.2 st ca thp v x ph thuc nhit Cht Thp X lng X lng va X c Nhit (oC) 1595 1595 1595 1595 st (poa) 0,025 0,02 0,20 2,0
- 42 -
Hai yu t nh hng n st ca x l: + Thnh phn ha hc ca x; + Nhit ca x. X axit d chy hn x baz nn khi nhit thp c st nh hn x baz. Khi nhit tng, st ca x axit v x baz u gim nhng st ca x baz gim mnh hn nn khi nhit cao st ca x baz li thp hn st ca x axit. thy r nh hng ca thnh phn n st ca x, ta xt gin ba nguyn ca x nhit 1600oC (hnh 3.2).
40 50 60 70
30
60
%SiO2
50 40
35 15 10
8 3 4 4 6
%CaO
5 20 30 40
30
50
60
%Al2O3
Hnh 3.2 Gin st ca x 1600oC
T gin ta nhn thy, nhit 1600oC, nhiu thnh phn x c th m bo chy long ( st ca x thp), nht l nhng loi cha t 48 55 %CaO, khi %CaO < 45% th st ca x ch ph thuc vo %CaO m t ph thuc vo t s SiO2 : Al2O3. Trng lng ring ca x: trng lng ring ca x cng thp th x cng nh v cng d tch ra khi kim loi. Trng lng ring ca x ph thuc thnh phn ca x, trong c nh hng ln nht l cc oxyt FeO, Fe2O3, MnO. Bng 3.3 cho trng lng ring v nhit chy ca mt s oxyt v hp cht trong x.
- 43 -
Bng 3.3 Trng lng ring v nhit nng chy ca mt s hp cht Hp cht FeO Fe3O4 Fe2O3 MnO MgO CaO SiO2 Al2O3 P2O5 MnS (CaO)3.P2O5 CaO.SiO2 Trng lng ring (g/cm3) 5,7 5,1 5,2 5,24 5,45 3,65 3,40 2,20 2,65 2,39 4,00 3,14 2,405 Nhit chy (oC) 1420 1538 phn hy 1560 phn hy 1785 > 2800 2572 1713 2050 1620 1670 1540
Nhit hm ca x: l lng nhit cn cung cp cho 1 kg x nung nng n n nhit nng chy, nng chy hon ton v qu nhit n nhit yu cu. Nhit hm ca x c th tnh theo cng thc gn ng sau:
q = 0,28t + 50
(kj/kg)
Trong t l nhit lm vic ca x. dn in ca x: dn in ca x c ngha ln trong mt s qu trnh nu luyn, c bit l khi luyn thp trong l h quang hoc l in x. dn in ca x tng khi tng nhit v trong thnh phn ca x cha nhiu cc oxyt baz, cacbit canxi. Sc cng b mt ca x: sc cng b mt ca x nh hng rt ln n vic tch chng khi kim loi. X c sc cng b mt ln th t dnh vo kim loi v d tch ra trong qu trnh nu luyn.
- 44 -
3.4. Cn bng nhit trong qu trnh luyn thp 3.4.1. Ngun nhit cung
Ngun nhit cung cp cho l trong qu trnh luyn thp c th chia lm hai dng: + Nhit ha hc. + Nhit vt l. a) Nhit ha hc: Nhit ha hc l nhit c cung cp do t chy nhin liu hoc do phn ng oxy ha khi kh tp cht sinh ra. Ty thuc qu trnh luyn, ngi ta c th dng cc ngun nhin liu sau: + Nhin liu rn: than cc, than gy, ci hoc g; + Nhin liu lng: du t; + Nhin liu kh: kh thin nhin, kh l cc, kh l cao. Nhit do phn ng oxy ho khi t chy tp cht: phn ng chy C, Si, Mn, P ... V d trong l betsme nhit ha hc ch yu do t chy Si, trong l tmat ch yu l do t chy P. b) Nhit vt l: nhit vt l do gang lng, nhit tch ca tng l hoc do khng kh, nhin liu... c nung nng mang vo. Trong cc l in ngun nhit vt l l do bin i in nng thnh nhit nng: nhit ca h quang in, nhit tr hoc nhit sinh ra do hin tng cm ng in t...
3.4.2. Ngun nhit chi

Nhit cung cp cho l, mt phn c dng nung nng, nu chy v qu nhit kim loi, x n nhit yu cu, cung cp cho cc phn ng thu nhit xy ra trong qu trnh nu luyn... gi l lng nhit c ch, mt phn b mt mt trong qu trnh nu luyn do truyn nhit cho l, truyn nhit ra ngoi, do kh thi mang theo ... phn nhit ny c gi l nhit tn tht. Trong qu trnh nu luyn cn m bo s cn bng ngun nhit cung v ngun nhit chi trong l.
- 45 -
Chng IV LUYN THP TRONG L IN H QUANG

4.1. c im v phn loi L in h quang l loi l c dng rt ph bin nc ta. u im ca l in l: + Nu c nhiu loi nguyn vt liu (gang, thp vn ...); + Chy hao kim loi t; + D dng iu chnh nhit nc thp; + Nu c nhiu loi thp, cht lng thp tt; Hn ch ca l in h quang l in nng t. 4.1.2. Phn loi Da vo cng sut bin p v dung tch cha thp, ngi ta phn ra: + L in h quang cng sut thng: 400kVA/tn. + L in h quang cng sut cao: 600 800kVA/tn. + L in h quang siu cng sut: > 800kVA/tn. Da vo ngun in, phn ra: + L in h quang xoay chiu: dng ngun in xoay chiu, l c ba in cc. + L in h quang mt chiu: dng ngun in mt chiu, l ch dng mt in cc. 4.2. Thit b 4.2.1. Cu to chung v nguyn l lm vic Hnh 4.1 trnh by cu to chung ca l in h quang, l gm cc b phn c bn sau: + Bung l; + Thit b nghing l; + Thit b nng h in cc; + Thit b in (my bin th v mng in). 4.1.1. c im
- 46 -
Hnh 4.1. Cu to tng th ca l in h quang 1) Vi phun oxy 2) in cc grafit 3) ng ht khi bi 4) Np l 5) V l bng thp 6) Ca thao tc 7) Thit b dch chuyn v l 9) B phn dn ng quay l 10) ta b phn dch l 11) Thit b quay np l 13) B phn quay khung l 14) Qut thng kh 15) B phn lm ngui in cc 16) Thit b nng h in cc 17) Dy cp in
L in h quang s dng ngun nhit l ngn la h quang sinh ra gia cc in cc v kim loi nu. Khi nu, in cc c h xung chm vo kim loi gy ra hin tng ngn mch, sau nng in cc ln cch mt kim loi mt khong cch nht nh, gia in cc v kim loi pht sinh ngn la h quang. Do h quang gy ra trc tip gia in cc v kim loi nu nn c gi l h quang trc tip, nhit ngn la h quang rt cao v nhit tp trung nn nhit truyn cho kim loi rt ln v - 47 -
ch yu l truyn nhit bc x. Theo mc nng chy ca kim loi trong bung l, in cc c iu chnh gi khong cch gia in cc v kim loi n nh, nh h quang chy n nh. 4.2.2. Bung l Bung l gm ba phn: y l, thn l v nc l (hnh 4.2). y l: lm nhim v cha kim loi v x. Phn trn y l c dng hnh cn, gc nghing 45o, phn di c dng chm cu. Chiu dy th xy y l thng t 650 700 mm, gm: + Lp manhdit thiu kt dy 180 200 mm; + Lp gch manhdit dy 295 mm; + Lp gch samt dy 130 mm; + Lp vn samt dy 30 mm; + Lp ba aming dy 10 mm. Ngoi cng l v l bng thp tm dy 20 mm.
D3
h3
H1 b a
h2 h1
10 0
d D1 D2
Hnh 4.2 S cu to bung l in h quang
Tng l: to khng gian cha liu, ng thi chu lc tc dng ca nc l. Chiu dy tng l thng t 350 700 mm, gm cc lp: - 48 -
+ Lp gch manhdit dy 285 mm. + Lp gch samt dy 130 mm. Nc l: c dng hnh chm cu, xy bng gch crm-manhdit hoc bng gch dinat, chiu dy khong 300 mm. nc l, khi xy cha ba l trng t ba in cc. Th xy y v tng l in h quang baz trnh by trn hnh 4.3. .
1 2 3 4 6 5
Hnh 4.3 Th xy tng v y l h quang baz 1) Lp manhdit thiu kt 2) Lp gch manhdit 3)Lp gch samt 4) Lp vn samt 5) Lp ba aming 6) V thp
Cc kch thc c bn ca bung l: thng khi thit k l, s liu cho ban u l cng sut l (T/h), t c th tnh c khi lng ca m kim loi nu, th tch ca kim loi v x. Trn c s , xc nh dung tch ni l v cc kch thc c bn ca bung l. Da vo hnh 4.2 ta c th tnh nh c th tch ni l:
r2 h2 h V = .h 1 + 1 + . 2 (R 2 + R + r 2 ) 8 6 3 Trong : (4.1)
r=
D d v R = 1 . 2 2
- 49 -
Cc kch thc ca ni l thng c chn theo chiu cao ni l H:

D 1 = 5H
R=
D1 5 = H 2 2
1 h 1 = .H 5
4 h 2 = H h 1 = .H 5 d = D1 2h 2 = 1 r = d = 1,7 H 2 Thay cc gi tr trn vo cng thc (4.1) ta tnh c:

V = 11,6H 3
17 H 5
Suy ra:
H=3
V 11,6
(4.2)
Cc kch thc khc ca tng l c chn theo chiu cao ni l H nh sau:

D 2 = D1 + 200 = 5H + 200 H1 = (2,1 2,2)H
[mm] [mm]
D 3 = (5,42 5,44 )H + 200 Chiu cao nc l:
[mm]
1 1 h 3 = D 3 7 8 Chiu rng ca l:
a = 0,3D 3
[mm]
Chiu cao ca l:
b = 0,8a .
Dung tch l mi thit k thng nh hn 30 40% so vi sau khi nu, do c th nu qu t 15 20% (bng 4.1).
- 50 -
Bng 4.1 Dung tch l h quang luyn thp Dung tch danh ngha (tn) 0,5 1,5 3,0 5,0 10,0 0,7 0,8 2,0 2,2 3,8 4,2 6,0 7,0 12,0 13,0 Nu bnh thng Ti trng cht (tn) L baz Nu cng bc 0,8 0,9 2,3 2,5 4,5 5,0 7,4 7,8 14,0 16,0 L axit 1,0 1,1 2,6 2,8 5,2 5,5 8,0 8,5 -
4.2.3. Thit b nng h in cc
Trong qu trnh nu luyn, mc kim loi di in cc thay i, in cc b mn dn... duy duy tr h quang chy n nh, ba in cc ca l cn phi chuyn ng ln xung ph hp. Thit b nng h in cc lm nhim v iu chnh in cc trong sut qu trnh nu luyn, m bo khong cch gia in cc v kim loi hoc x duy tr ng theo yu cu.
1 5
Hnh 4.4 Thit b nng h in cc 1) Gi lp in cc 2) Tr dn hng 3) H thng dn ng 4) Kp in cc 5) i trng
Thit b nng h in cc gm: + Gi lp in cc; - 51 -
+ H thng dn ng; + Tr dn hng. Gi lp in cc dng kp in cc, c cu kp c lm ngui bng nc. Dn ng c cu iu chnh nng h in cc thc hin bng h thng c kh hoc h thng thy lc. Chuyn ng iu chnh c t ng ha.
4.2.4. C cu nghing l
i vi l in h quang ra thp qua mng ra thp bn hng khi ra thp phi nghing l. nghing l c th dng c cu c kh hoc thy lc.
4.2.5. Thit b in
S mng in v bin p ca l in h quang trnh by trn hnh 4.5. Dng in cao th t ng dy (1) qua cu dao khng kh (2), cu dao du chnh (3), cun cm (7), my bin p (9) ti in cc (12) v sinh ra h quang gia in cc v kim loi (13). Cu dao khng kh (2) dng ng m thit b in ca l, n ch c ng m khi cu dao du chnh (3) m. Cu dao du chnh dng ngt mch in. V y c dng cao th chy qua, nn phi dng cu dao ny m bo an ton (cu dao u chnh trit tiu c tia la in pht ra khi ngn mch). m bo an ton cho mch in ca l, ngi ta phi dng h thng ng h o v r le bo v (6), khi dng in hay in p tng qu t ngt, n c kh nng t ng ngt mch. Cun cm (7) ca my bin th c kh nng to ra sc in ng cm ng bin h quang gin on thnh h quang lin tc, do h quang v dng in n nh, liu s chng chy, nhng khi c cun cm th s tng tiu hao in, khng s dng ht cng sut ca my bin p, h s cos gim. V vy khi nu chy xong, h quang v dng in n nh th phi ct cun cm khi mch, thc hin vic dng cu dao u in cm (8). Bin p (9) ch yu i dng in h th ph hp vi tng giai on nu luyn. Yu cu ca bin p l h quang l cch in rt tt, c kh nng qu ti ln chu c on mch v qu ti thng xuyn.
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2 5
10
9 11
12
13
Hnh 4.5 S thit b in ca l in h quang 1) ng dy cao th 2) Cu dao khng kh 3) Cu dao du chnh 4) B phn o dng 5) B phn o p my bin p 6) ng h o v r le bo v 7) Cun cm 8) Cu dao du cun cm 9) My bin p 10) Cu dao i in p 11) ng h o, thit b bo v v t ng iu chnh in cc 12) in cc 13) Kim loi
- 53 -
Ty theo tng giai on nu, ngi ta yu cu nhng cp in p khc nhau. Do , my bin p cn c nhiu cp in p, thng l su cp in p ty theo cch mc hnh sao ( ) hay tam gic ().
a)
b)
Hnh 4.6 Cc phng php ni cun dy my bin p a) Mc hnh sao b) Mc tam gic Th d su cp in p ca my bin p l: Khi mc tam gic: 260 V - 220 V - 180 V. Khi mc hnh sao: 150 V - 127 V - 104 V. Ty theo tng giai on nu, ta s dng in p thch hp, thng thng: Giai on nu chy: Giai on oxy ha: Giai on hon nguyn: 240 380 V. 160 200 V. 140 115 V.
Cng sut my bin p xc nh theo cng thc:

P = 3.U.I. cos
Trong : P - cng sut my bin p; U, I - in p v cng dng in. Theo yu cu nu luyn, cng sut gim dn t giai on nu chy sang oxy ha n hon nguyn (hnh 4.7).
- 54 -
8000 7000 6000 5000 4000 3000 2000 1000 0 210V
267V
1700 210V 210V 210V 157V 157V 1600 1500
121V
121V
Hnh 4.7 Ch in cho m luyn thp l h quang 30 tn
gim cng sut c th gim U hoc I. Khi in p vng h th c nh, gim I th phi tng chiu di h quang (tng in tr). Ngc li khi gim U th chiu di h quang phi ngn li. Bng 4.2 in p ti thiu sinh h quang ph thuc vt liu ch to in cc in cc in cc than - than in cc than - kim loi in cc than - x baz in cc than - x axit in p sinh h quang (V) 17 26 9 30
Do , khi bt u chy l, nhit l cn thp, h quang pht sinh gia cc than v kim loi khng vng, n nh h quang ngi ta cho thm cc mnh in cc ln trn kim loi. Khi trong l c x baz th h quang d n nh nn ta c th ct cun cm ra khi mch in.
4.2.6. in cc: lm nhim v gy h quang in, c ba loi:
+ in cc t thiu; + in cc cacbon; + in cc grafit.
- 55 -
in cc t thiu chuyn dng cho sn xut fer. in cc dng cho luyn thp thng dng in cc grafit. in cc cacbon hin nay t dng. Theo cng sut l, in cc grafit c phn ra: + in cc grafit thng; + in cc grafit cng sut cao; + in cc grafit siu cng sut. in cc c ch to dng hnh tr, u cui c phn lp u ni hnh tr hoc hnh cn c ren (hnh 4.8).
Hnh 4.8 Cu to in cc 1) Thn in cc 2) u ni
Cc ch tiu ha l ca in cc grafit thng dng trnh by bng 4.3. Bng 4.3 Cc ch tiu ha l ca in cc grafit thng dng ng knh in cc (mm) Ch tiu 75 130 cp cao in tr sut min (.mm2/m) Cng b gy min (Mpa) Thnh phn tro max (%) Thn ni Thn ni Thn 8,5 8,5 7,85 11,3 0,5 cp 1 10 150 200 cp cao 9,0 8,5 7,85 11,3 0,5 cp 1 11 250 350 cp cao 9,0 8,5 6,37 9,81 0,5 cp 1 11 400 500 cp cao 9,0 8,5 6,37 9,81 0,5 cp 1 11
- 56 -
Mt thc min (g/cm3) bn nn min (MPa)
Thn Thn ni
2,18 19,6 29,4
2,.18 19,6 29,4
2,18 17,7 29,4
2,18 17,7 29,4
Cng dng in cho php ph thuc ng knh in cc (bng 4.4). Bng 4.4 Cng dng in cho php ng knh in cc 75 100 125 150 200 250 Cng dng in cho php (A) 1000 1400 1500 2400 2200 3400 3500 4200 5000 6900 7000 10000 ng knh in cc 300 350 400 450 500 Cng dng in cho php (A) 10000 13000 13000 18000 18000 23000 22000 30000 25000 34000
Ch tiu ha l ca in cc grafit siu cng cng sut cho bng (4.5) Bng 4.5 Ch tiu ha l ca in cc grafit siu cng cng sut ng knh in cc (mm) Ch tiu 225 400 Thn Hm lng C (%) Tro (%) Xp (%) Mt (g/cm3) in tr sut (mm2/m) 99,3 0,2 20 24 1,65 1,72 5,0 6,5 u 99,3 0,2 20 24 1,74 1,80 4,5 5,5 400 600 Thn 99,3 0,2 20 23 1,66 1,73 4,5 5,75 u 99,3 0,2 20 23 1,74 1,81 4,0 5,0
- 57 -
Un (MPa) Nn (MPa) M un n hi (GPa) H s dn nhit (w/m.oC) H s gin n nhit (10-6/oC)
9,0 14,0 6,6 10,0 6,5 11,0 175 260 0,5 1,0
14,0 20,0 12,5 18,0 240 260 0,4 0,9
8,5 13,5 6,0 9,5,0 6,0 11,0 210 280 0,3 0,6
13,0 19,0 12,0 17,0 250 320 0,75 0,6
i vi in cc grafit cn lu : + Khi bo qun in cc grafit cn trnh ma gi lm m in cc, trong qu trnh vn chuyn phi ht sc cn thn trnh va p, trc lc s dng cn sy kh nhit 100oC. + Khi ni in cc cn vn cht trnh to khe h, dn n sinh h quang mi ni khi dng in i qua. + Khi np liu trnh liu va p vo in cc.
4.3. Cng ngh nu luyn 4.3.1. Nguyn vt liu
Nguyn vt liu dng luyn thp trong l h quang gm: + Nguyn liu kim loi: thp ph, gang, phe-r hp kim, st xp.
+ Liu to x: gm vi, hunh thch ... + Liu oxy ha: qung st, kh oxy ... 4.3.2. Cng ngh luyn thp thp trong l in h quang baz a) Giai on nng chy
Trong giai on ny liu c nung nng n nhit nng chy v chuyn sang th lng. y l giai on quan trng trong qu trnh luyn thp, chim ti 60% thi gian nu luyn.
- 58 -
u tin cht mt lp thp ph m di y l trnh va p gy hng y l khi cho liu thi ln vo. Tip theo cho gang thi vo khong 50%, sau cht mt lp thp ph ln trn. Khi bt u nu luyn, liu cht gn y l, h quang nm gn nc l, ch dng khong 50% cng sut trnh lm hng nc l. Sau khi liu di in cc nng chy, kim loi lng tp trung xung y l, xung quanh in cc to thnh h (ta gi giai on ny l giai on o h), tng cng sut l ln cc i (Wmax) v tip tc iu chnh in cc i xung duy tr h quang. Khi nc thp tp trung y l dn dn dng ln v in cc xung gn mt nc thp, iu chnh in cc i ln theo tc dng ca mt nc thp. Trong qu trnh nu chy, liu st thnh l kh nng chy v xa h quang, tng qu trnh nng chy ngi ta c th thi kh oxy vo qua cc vi phun b tr quanh thn l. Khi liu rn nng chy ch cn cc nh nm trong thp lng, cho thp ph vo v tip tc nu chy, khng nn cho thp ph vo khi liu nng chy hon ton, v nh vy d gy bn te kim loi lng gy nguy him. Trong giai on ny, nhit tiu tn ln, nu chy nhanh cn phi dng cng sut l ln, kt hp thi thm oxy. Cui giai on nu chy ly mu phn tch thnh phn ha hc (ch yu l phn tch cacbon v phtpho).
b) Giai on oxy ha
Trong giai on ny xy ra cc phn ng oxy ha cc nguyn t C, Si, Mn, P, S, ng thi tin hnh kh kh v tp cht phi kim. Do cc phn ng oxy ha to nhit nn cng sut l giai on ny khng cn ln (ch cn khong 50% Wmax). Trong giai on ny Si b kh u tin, khi Si ch cn 0,02% th Mn bt u b kh. Trong giai on nu chy, Mn b t chy khong 50%, sau giai on oxy ha tip tc b t chy cn li 0,2%. kh P kim (B) phi cao, hm lng (FeO) cao v nhit (T) thp. Khi kh S kim phi cao, nhng hm lng FeO trong x cng thp cng tt v nhit phi cao.
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Trong giai on oxy ho cm m bo [C], [P] v nhit t yu cu. i vi [S] trong giai on ny t quan tm nhng cui giai on cng phi xc nh [S] chun b cho giai on x l tip theo.
c) Giai on hon nguyn
Giai on hon nguyn ch duy nht luyn trong l in h quang mi c cn trong cc l khc khng c. Mc ch ca giai on ny l kh [S] nu cn, sau kh [O] v hp kim ho, ng thi nng nhit thp lng. Kh oxy bng phng php khuch tn: u tin tin hnh co b x oxy ha, sau tin hnh to x hon nguyn, thnh phn gm vi (CaO) v cht tr dung (CaF2) v bt than, khi kim ca x tng, hm lng (FeO) gim xung, lng dng cht to x khong 4 7%. Vi lm tng kim ca x. Cht tr dung CaF2 lm gim nhit nng chy ca CaO. Bt than:
(FeO) + C = (Fe) +{CO}
Lc ny kh [S] rt tt v B tng, (FeO) gim v nhit cao. Thc t trong giai on ny, hm lng kh [H], [N] vn cn do dng h quang a vo. Khi a bt than vo cn trnh ch dng h quang, v khi gp dng h quang:
CaO + 2C Tcao CaC + CO FeO + CaC = (Fe) + (CaO) + CO
Cui giai on hon nguyn cho Si v Mn vo t hm lng yu cu ca mc thp.

PFe Mn = Trong : C1 : hm lng cn c trong thp. C2: hm lng cn li trong thp lng trc khi cho fer vo. Sau khi ra thp, ch lng 3 5 pht, ng thi tp cht ni ln v tng s ng u thnh phn mi tin hnh rt khun. Q[C 1 C 2 ] %Mn (Fe Mn )
- 60 -
i vi quy trnh luyn thp hin i trong l in siu cng sut v c lin tc, giai on nu luyn thng rt xung di mt gi, l in ch lm hai nhim v nu chy v oxy ha, cn tinh luyn, kh [O], kh tp cht, kh kh v hp kim ho tin hnh ngoi l.
4.3.3. Tinh luyn ngoi l

Tinh luyn ngoi l c th tin hnh bng phng php chn khng x hoc thi kh (xo trn). Di y trnh by phng php tinh luyn bng thi kh l phng php ph bin trong cng ngh luyn thp hin i, l tinh luyn bng l LF (Ladle Furnace). S cu to l LF trnh by trn hnh 4.9.
8 9
B 2 A C D
7 Gch manhedit A B
5 6
3 Gch ZrO.C D
Gch xp thu kh C
Tm chn chuyn ng
Hnh 4.9 S cu to l LF 1) Np l 2) Tng l 3) y l 4) Gch xp 5) L rt 6) Tm chn 7) ng dn kh acgng 8) Ca quan st 9) Ca vo liu
Np l c cu to tng t l in h quang cng sut thng. Tng l gm 4 lp (mt ct A) tnh t ngoi vo gm: v l bng thp, lp aming, lp gch xp cch - 61 -
nhit v lp gch lm vic. Phn tng l ngang mc cha x (mt ct B), lp lm vic xy bng gch manhedit. phn y l c b tr cc vin gch xp thu kh (mt ct C) v l thi kh (mt ct D). Bn di l thi kh t hai tm chn c l cho kh i qua, mt tm t c nh, mt tm chuyn ng qua li khi lm vic. tinh luyn v kh kh, sau khi cho thp lng vo l, tin hnh to x hon nguyn, gy h quang chm trong x v thi kh acgng vo l. Khi sc kh acgng vo l, cc bt kh to ra s xo trn mnh thp lng lm tng qu trnh ni ca cc ht ln rn, ng thi kh [H], [N] khuch tn vo cc bt kh v b cun ra ngoi. Nh s xo trn mnh ca thp lng s kh [S] cng tng ng k. Qu trnh tinh luyn tng t nh giai on hon nguyn trong l in h quang.
- 62 -
Chng V LUYN THP TRONG L IN CM NG V MT S L IN KHC

5.1. c im v phn loi 5.1.1. c im L in cm ng s dng in nng bin thnh nhit nng nh hiu ng cm ng in t. L in cm ng c nhiu u im hn so vi l h quang: + C th luyn c thp C rt thp (khng c s tng C do in cc); + Thnh phn kim loi ng u hn (nh s khuy trn kim loi tt di tc ng ca lc in t); + Nng sut l cao, ct chy hao cc nguyn t hp kim; + D khng ch thnh phn v nhit kim loi; Nhc im: + Nhit ca x thp nu khng c bin php x l thm; + bn lp o l baz thp. 5.1.2. Phn loi Theo cu to, l in cm ng c chia thnh hai loi: loi c li st v loi khng c li st, luyn thp thng dng loi khng c li st. Theo c tnh ca dng in ngun cung cp, l in cm ng c chia ra: + L cao tn: lm vic vi tn s my pht khong 100 200 kHz. + L trung tn: lm vic vi tn s my pht khong 500 1.000 Hz. + L thp tn: lm vic vi tn s 50 60 Hz. 5.2. Thit b 5.2.1. S cu to v nguyn l lm vic L in cm ng khng c li st (hnh 5.1) lm vic ging nh mt bin th khng kh m cun s cp l cc vng cm ng v cun th cp l lp mt ngoi ca kim loi nu.
- 63 -
Khi c dng in tn s cao chy qua cun s cp, th trong m liu kim loi sinh ra sc in ng cm ng:
E 2 = 4,44.f .n
[vn]
(5.1)
Trong : - t thng; f - tn s dng in; n - s vng dy cm ng.

3 1
Hnh 5.1 S cu to l in cm ng khng c li st 1) Ni l 2) Vng cm ng 3) Kim loi nu
Sc in ng cm ng E2 sinh ra dng in cm ng I2, ch yu tp trung lp mt ngoi cc liu, lm kim loi b nung nng v chy lng. Chiu su lp b mt cc liu, ni m mt dng in cm ng t gi tr ln c gi l chiu su thm t c th xc nh theo cng thc sau:
= 5,03.10 3 Trong : - in tr sut ca vt liu [.cm]; - t thm ca vt liu; f - tn s dng in [Hz]. Nhit nng to ra c th xc nh theo cng thc: .f
- 64 -
W2 = 2.I 2 .n 2 . 2 . Trong : I - cng dng in (A); N - s vng cm ng;
d2 . ..f .10 9 h2
[W]
(5.2)
- in tr sut vt liu (.cm); - t thm; f - tn s (Hz); d2 - ng kinh trung bnh ca liu (cm); h2 - chiu cao ca kim loi trong ni l (cm); T phng trnh (5.1) v (5.2) ta thy tng E2 v W2 cn tng n v f, thng thng ngi ta tng f. Tn s ti thiu i vi mt kim loi nu xc nh theo cng thc:
f min 2,5.10 9
e d2
e - khe h gia vng cm ng v m liu (cm); d - ng knh trung bnh ca ni l (cm). i vi l cm ng khng c li st, khe h gia vng cm ng v m liu ln, t thng r rt ln nn h s cng sut thng khng vt qu 15%. Dng in trong vng cm ng v thp lng ngc chiu nhau, hai vt dn ny li ng tm nn y nhau lm cho thp lng c xo trn tt.
5.2.2. Cc b phn c bn ca l
L in cm ng c nhiu b phn, song ta c th chia ra hai phn chnh: + Mng in l; + L nu.

a) Mng in l cm ng: gm c ng c xoay chiu, my pht tng tn s, my
in kch thch mt chiu t in, cun cm ng.
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ng c in: thng dng ng c in khng ng b vi rto ni ngn mch (hiu in th ti 500V, s vng quay c 300 vng/pht, c cung cp bi ngun in tn s cng nghip. My pht tng tn: thng dng ba loi: my pht quay, my pht n in t v my pht phng tia la. My pht quay c tn s 100 10.000 Hz, cng sut my pht cn khong 0,3 1 kw/kg liu. Loi ny thng dng cho l th nghim dung tch c 8 10 kg. My pht n in t v my pht phng tia la c tn s 200 1.000 kHz, thng dng cho cc l dung tch nh trong cng nghip v th nghim. Cun cm ng: thng lm bng ng ng c tit din ngang l hnh trn, ch nht hoc bu dc. Vt liu ch to l ng k thut in c dn in cao, kch thc c tnh ton sao cho va m bo yu cu v dn in, va phi m bo lu lng nc lm ngui vng cm ng. t tn hao in nht th chiu dy thnh ng phi m bo iu kin:
t > 1,3.
Trong : - chiu su thm t. S vng cm ng cng tng th lng nng lng in chuyn thnh nhit nng trong m liu cng ln, nn cng tng s vng th tn tht cng gim, tuy nhin vn phi m bo t l: H = 1,1 1,3 h Trong : H - chiu cao cun cm ng; h - chiu cao kim loi trong ni l. Vng cm ng c lm ngui bng nc, p sut nc 1atm, nhit nc ra khong 35 - 45o. T in cun cm ng: gim cng sut my pht in cung cp cho l v nng h s cos (thng khng qu 0,15) ngi ta thng mc song vi cun cm mt h thng t in (gi l t b). Khi mc t b, gc lch pha gia dng in v in p s gim, h s cos tng v dn ti 1. - 66 -
C4 4 L2 8 C1 C2 C2 L2 L2 L1 C1 2 7 3 2 5 6 R2 R2
C3
L3
L4
Hnh 5.2 S h thng in ca l cm ng 1) B chnh lu ant 2) My pht cao tn 3) Chnh lu ph 4) Mch l nu
BA
- 67 -
iu kin t cos = 1 l:
C= Trong :
1 4 f 2 L
2
C - in dung ca t b; f - tn s dng in; L - t cm ca cun cm. Hnh 5.2 trnh by s mch in vi my pht n in t ca mt l in cm ng. Mch in gm: bin p ant BA, b chnh lu ant (1), my pht cao tn (2), b chnh lu ph (3) v mch l nu (4). B chnh lu ant dng su n gadotron (D1D6), bin p cao tn gm hai cun dy L3 v L4..
b) B phn l: gm ni l, khung l v thit b nghing l. B phn quan trng nht
l ni l, n c ngha rt ln v kinh t v k thut. Ngoi cc yu cu chung, ni l cm ng cn phi m bo yu cu thnh mng, khng dn in gim bt tn tht in, d ch to, sa cha. Ni l axit: c m bng ct thch anh, thnh phn: SiO2: 99 99,5%, Fe2O3: 0,5%, CaO: 0,25%, Al2O3: 0,2%, m: 0,5%. ht v t l trn nh sau: Thch anh c ht 5 6 mm Thch anh c ht 2 3 mm Thch anh c ht 0,5 1 mm Thch anh bt Axit boric k thut m. Ni l baz: c m bng hn hp ct manhdit hm lng MgO 85%, 4% SiO2, 0,1% CaO, 1% Al2O3, 2% Fe2O3. Cht dnh l axit boric, t st hoc nc thy tinh. Thnh phn hn hp kh: Ct manhdit : 90 94,5%.
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: 25%. : 20%. : 30%. : 25%. :1,72 %.
bn ni l axit tng i cao, vi l dung tch 1,4 tn c th dng c 150
t st chu la Axit boric Lng nc
: 5 9%. : 1 1,5%. : 5 7% (so vi khi lng kh).
bn ni l baz thp hn l axit, thng ch vo khong 10 100 m, l cng ln tui th cng thp. Ni l c th m trc tip hoc m ngoi sau a vo. Khi m trc tip, u tin t lp cch nhit aming vo pha trong cun cm ng v y, ph lp hn hp p y ni dy khong 20 40 mm xung y ri m cht. Tip tc t khun p ni vo v cho hn hp vo tng lp v m cht. Khun p ni ch to bng thp tm c khoan l ng knh 3 mm, v ni l bng thp dy 5 7 mm. Sau khi m xong c th sy s b bng ci hoc than sau sy bng in trc tip trong l. Qu trnh sy v thiu kt l gm cc giai on: + Sy kh: lm bc hi m, nhit sy 100 150oC. + Lm bc hi nc hydrad: nhit nung 600 800oC, thi gian 30 pht. + Thiu kt: nhit bng nhit nng chy ca kim loi, thi gian 30 pht. Sau khi nu ln u, ni l c thiu kt cn v l chy lun. Sau hai ba ln nu th ni l c thiu kt hon ton. Kch thc cun cm v ni l ca l cm ng khng li cho bng 5.1. Bng 5.1 Kch thc cun cm v ni l ph thuc dung tch l. Cng sut my pht (kw) 1400 1400 1200 680 150 8000 5000 4000 1400 250 1300 1170 1100 830 650 Dung tch l (kg) Kch thc cun cm (mm) Cao ng Knh trong 1380 1180 970 720 560 Chiu su 1200 1100 970 720 560 Kch thc l (mm) Chiu dy y 200 140 500 200 304 Chiu dy thnh Trn 110 100 90 90 30 Di 150 130 125 130 48
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5.3. Cng ngh luyn thp trong l cm ng
Khi nu thp trong l in cm ng, yu cu phi bit thnh phn ha hc ca nguyn liu em nu cng nh phi liu m liu chnh xc, v thi gian nu nhanh ch c th phn tch kp C v Mn hoc C v Si. Kch thc liu cn ph hp vi dung tch l v tn s dng in, l cng ln v tn s dng in cng b yu cu kch thc liu cng ln. Kch thc liu nh nht nh sau: l tn s 500Hz kch thc liu 20 mm, l tn s 1.000 Hz kch thc liu 10 mm, l tn s 10.000 Hz kch thc liu 5 mm. Khi cht liu, xp liu cng cht cng tt, liu c sy trc th nu chy s nhanh hn v t 750oC tr ln thp thm t tt hn. Trong giai on nu chy, nhit vng st thnh ni cao hn gia l, gia l cao hn vng y, cn nhit vng trn st vi x thp nht. Do nhit vng di cao hn vng trn nn khi liu vng di chy lng, vng trn cha chy lng c th gy ra hin tng treo liu, khc phc hin tng ny c th dng kh oxy thi vo mt trn. Trong l cm ng, sau khi nu chy xong thng tin hnh iu chnh thnh phn, kh oxy v ra thp.
5.4. Thit b v cng ngh nu thp trong mt s l in khc 5.4.1. Nu thp trong l in x
L in x dng luyn li nhm nng cao sch ca thp, s nguyn l cu to ca l trnh by trn hnh 5.3. L gm y l (1) c lm ngui bng nc, tng l (2) xy bng gch chu la. in cc kim loi (3) l kim loi cn nu li c th nng ln h xung nh c cu nng h in cc (4). Ngun in (9) c ni vi y l v in cc. Nguyn l lm vic: sau khi np cht to x vo l, gy h quang, nhit ca h quang lm nng chy x to ra lp x lng, khi in cc tip xc vi x lng h quang tt, dng in tip tc chy qua lp x lng c in tr ln lm pht sinh nhit, tip tc lm nng chy in cc kim loi. Cc git kim loi lng i qua lp x s c kh tp cht v tp trung xung y. Do c lm ngui nhanh t y, kim loi kt tinh nh - 70 -
hng t di ln trn lm cho tp cht tip tc b y ln pha trn, nh thu c thi kim loi c sch cao.
4 3
6 7 8
~
9
Hnh 5.3 S nguyn l l in x 1) y l 2) Tng l 3) in cc 4) C cu h in cc 5) X 6) Kim loi lng 7) Kim loi kt tinh 8) Nc lm ngui 9) Ngun in
5.4.2. Nu thp trong l in h quang chn khng
S cu to tng t l in x nhng khng dng x tinh luyn m dng mi trng chn khng.
4 3
6 7 8
~
9
Hnh 5.4 S nguyn l l in x 2) y l 2) Tng l 3) Chp chn khng 4) C cu h in cc 5) in cc 6) Kim loi lng 7) Kim loi kt tinh 8) Nc lm ngui 9) Ngun in
- 71 -
Tng l (2) trc y xy bng gch chu la nhng hin nay thng c thay th bng hp nc. in cc kim loi b nng chy do nhit ca h quang. Kim loi nng chy trong mi trng l l chn khng, trnh c ho tan kh, ng thi vic tch kh ho tan trit hn, kt hp vi kt tinh nh hng, tp cht b dn ln phn trn ca thi, ta thu c kim loi phn di c sch rt cao. L in h quang chn khng dng luyn thp siu sch, thp cht lng cao.
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Chng VI LUYN THP TRONG L THI

6.1. c im v phn loi Luyn thp trong l thi (cn gi l l chuyn) l phng php luyn thp ra i sm nht, qua nhiu giai on pht trin, hin nay vn c coi l mt phng php luyn thp quan trng trong lnh vc sn xut thp. L thi s dng nguyn liu kim loi l gang lng t l cao hoc l c chuyn n, bng cch thi khng kh hoc oxy vo gang lng t chy bt cc tp cht ch yu trong gang chuyn gang thnh thp. Nhit cp cho l gm hai ngun chnh: + Nhit vt l: do gang lng mang vo, nhit tch ca th xy l; + Nhit ha hc: sinh ra do t chy cc tp cht trong qu trnh luyn. Theo phng php thi, l c phn ra ba loi chnh: L thi y: thi khng kh t y, gm: + L Betsme: tng l axit (l thi y axit). + L Tmat: tng l baz (l thi y baz) L thi sn: thi khng kh t bn hng, gm: + L chuyn thi sn axit. + L chuyn thi sn baz. - L thi nh bng oxy (l LD): thi oxy t nh Mt vn ht sc quan trng trong luyn thp l thi l gii quyt nhit nc thp. Lng nhit vt l trong cc trng hp chnh lch t, nhng lng nhit ha hc th rt khc nhau ph thuc vo phng php thi v tnh cht tng l. Trong l thi y axit (l Betsme) v l thi sn axit ngun nhit ha hc ch yu l do t chy Si, trong l thi y baz (l Tmat) l P, trong l thi sn baz l Si v P. Mt khc, khi thi y ton b khng kh lnh i qua kim loi lng nn tn hao nhit ln hn khi thi sn. Nhit l thi y thp, cht lng thp khng tt nn hin nay t c s dng, tr l thi y baz cn c s dng nhng vng c gang nhiu P. - 73 -
O2 Nc
a)
b)
c)
Hnh 6.1 S nguyn l cc loi l chuyn a) L thi y b) L thi sn c) L thi nh bng oxy
L thi nh bng oxy (l LD: vit tt Lintz Donawit ni u tin xy dng l LD) l phng php luyn thp ra i sau nhng tc pht trin rt nhanh v tr thnh mt trong nhng phng php luyn thp ch yu hin nay trn th gii. u im ca l LD: + Phm vi s dng nguyn vt liu rng: s dng c mi loi gang lng luyn thp, ngoi gang lng c th dng c thp vn (c th dng ti 30% trong m liu) hoc qung st. + Nu c nhiu loi thp: thp C, thp hp kim thp, mt s mc thp hp kim cao, cht lng thp khng thua km thp l mactanh. + Hiu sut sn xut cao: thi gian nu luyn ngn, nng sut cao (2 l LD 40 tn c sn lng tng ng 4 l Mactanh 250 tn). + Vn u t xy dng v chi ph sn xut thp (vn u t xy dng ch bng 40 50 % , chi ph sn xut ch bng 55% so vi l mactanh cng sn lng). Nhc im ca l LD l bi khi v chy hao nhiu, mt khc luyn thp t gang c Si >1,5% hoc P cao, luyn thp C > 0,6% c nhiu kh khn.
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Hin nay, l thi y, nht l l thi y axt t c s dng, bi vy trong chng ny ch yu gii thiu thit b v cng ngh luyn thp trong l thi sn v l thi nh bng oxy . 6.2. Luyn thp trong l thi sn 6.2.1. Cu to l L thi sn c hai dng: dng hnh ng (hnh 6.2a) v dng hnh tang trng (hnh 6.2b).
a)
b)
Hnh 6.2 S nguyn l cc loi l chuyn
a) Dng hnh ng b) Dng tang trng L dng hnh tang trng c u im: + Hnh dng pha trong ph hp vi s chuyn ng ca kh nn tng l mn u hn; + Mt gi di bng nhau v cch u tng l i din nn gi phn b u n hn; + Hnh dng ni l ph hp vi chuyn ng ca cht lng, thun tin cho chuyn ng i lu, tng tc oxy ha tp cht;
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+ Din tch b mt ln, chiu su cn, thun tin cho s tip xc v phn ng gia thp lng v x. Tuy nhin l hnh tang trng c cu to phc tp, nng n, ch thch hp vi l dung tch ln, cn cc loi l dung tch di 5 tn thng hay dng l dng hnh ng. 6.2.2. Cng ngh luyn thp trong l chuyn thi sn baz a) c im u im ca phng php luyn thp trong l chuyn thi sn baz: + Hm lng P trong gang lng cho php thay i trong phm vi rng (0,1 1,0%); + C kh nng kh S; + Khng cn giai on thi sau kh P; + Thit b n gin, vn u t thp, thi gian xy dng nhanh; Nhc im: + Nhit ha hc thp, din tch ta nhit ca l kh ln do m bo nhit thao tc cn dng gang lng c nhit cao; + bn tng l thp; + Hao tn gang ln do chy hao v bn te; + Cht lng thp thng khng n nh. b) Ch thi luyn: gm ch gi, ch nghing l v ch x. Ch gi: ch gi ph thuc dung tch l, thnh phn nc gang, nu chn gi c lu lng ln v p sut cao th thi gian nu luyn ngn, nhng nu chn qu cao th gy bn te kim loi v x. Lu lng gi hp l xc nh theo cng thc:
Q= Trong :
[m3/pht]
W - lng khng kh cn thit trn mt tn gang lng, i vi gang phtpho thp W = 500 m3/tn. - thi gian thi (pht), thng thng = 18 22 pht.
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p sut gi cn khuy trn c kim loi, nu qu thp khu vc phn ng tp trung trn b mt gn mt gi lm tm thc mt gi, nu qu cao li ph hy o l. p sut gi ph thuc dung tch l tham kho bng 6.1. Bng 6.1 p sut gi khi thi luyn Dung tch l (tn) 0,5 1,0 1,5 3,0 6,0 10 p sut gi (atm) 0,15 0,2 0,2 0,25 0,30 0,40 0,60
Ch nghing l: mt c im quan trng ca luyn thp trong l thi sn l l c th dng ch quay nghing l trong qu trnh thi luyn thay i su thi luyn (khong cch t mt gi n mt thong nc thp trong l). Ty thuc su thi luyn ngi ta chia ra: + Thi treo: mt gi nm trn mt thong nc thp, khong cc t mp di mt gi n mt thong nc thp > 20 mm. + Thi mt: mt gi nm trn mt thong nc thp, khong cc t mp di mt gi n mt thong nc thp t 0 20 mm. Thi nng: mt gi nm di mt thong nc thp, khong cc t mp trn mt gi n mt thong nc thp t 0 60 mm. Thi su: mt gi nm di mt thong nc thp, khong cc t mp trn mt gi n mt thong nc thp t > 60 mm. Khi thi treo, mt gi nm trn mt thong nc thp v cch xa mt thong nc thp, kh nng khuy trn nc thp ca dng kh km, vi b thi dt v pha tng i din mt gi, dn n kh to x khng li cho vic kh P v S, ng thi lm tng s n mn tng l, Fe b oxy ha nhiu v d gy bn te kim loi. Khi thi mt, mt gi nm trn mt thong nc thp v gn mt thong nc thp, do kh nng khuy trn nc thp ca dng kh ln, phn ng chy ca - 77 -
cacbon hon ton hn, lng FeO thch hp cho to x nn x c to nhanh, thun li cho vic kh P v S, thi gian nu rt ngn nn gim [N] trong thp. Thi mt l thao tc c bn ca l chuyn. Khi thi nng, mt gi nm di mt thong nc thp, t to ra FeO. V vy khi x cha chy lng khng nn thi nng, khi x chy trnh x qu long gy bn te c th thi nng. Khi thi su, mt gi nm su di mt thong nc thp, lng FeO trong x thp nn x kh chy, lm tng tn hao nhit do nung khng kh v tng s ha tan kh, do vy khi thi luyn nn trnh thi su. Trong qu trnh thi luyn, do kim loi b chy hao, mt thong nc thp h thp lin tc, duy tr ch thi mt cn phi c ch nghing l chnh xc. Hnh 6.3 trnh by s thay i gc nghing l ti ba thi im khc nhau.
max
=0
max
Hnh 6.3 S thay i gc nghin l duy tr ch thi mt
a) Lc bt u thi b) Gia qu trnh thi c) Cui qu trnh thi dm bo cui qu trnh thi, mp di mt gi v mt nc thp cng v tr nm ngang th phi m bo xc nh chnh xc gc cht liu (gc gia trc mt gi v mt nc gang khi cht liu xong). Bng 6.2 cho gc cht liu thch hp i vi mt s l thng dng.
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Bng 6.2 Gc cht liu thch hp khi nu thp trong l thi sn Dung lng l (tn/m) 3 6 Gc cht liu max () L thi hnh ng 14 22 14 20 L thi hnh tang trng 8 14 6 12
Ch x: c ba ch x: x n, x kp v x lu. X n l x ch to mt ln trong sut m nu bng cch cho vo cng mt lc hay tng t nhng sut qu trnh thi luyn khng co x. u im ca to x n l thao tc n gin, tit kim thi gian v gim nh cng lao ng. to x n ngi ta cho vo l vi, vi lng dng tng cng khong 50 80 kg cho mt tn thp, lng x khong 10 15% khi lng thp, baz lc ra thp B 3. X n c s dng khi luyn thp cacbon thp t gang lng c %P thp (%P <0,20%) v %S, %Si u thp. X kp l ch x c hai ln to x, trc khi thi to x t 1, sau khi bt u thy c ngn la bo hiu s chy ca cacbon th nghing l, ngng gi, co x t 1 (cha nhiu SiO2 v mt phn P, S) ra, cho cc cht to x t 2 vo v tip tc thi luyn. baz ca x t 1 khong 1,0 1,5, t 2 khong 2,0 3,5. u im ca x kp l kh P v S hiu qu hn x n, tit kim c vi (do co bt SiO2 v P2O5), nhc im l tn thm thi gian, tng tn hao nhit lng, gim FeO trong x. X kp thng dng khi gang c hm lng P v Si tng i cao. X lu tng t x kp nhng gi mt phn x ca m trc lm x t 1 cho m sau, ty theo %P v %S trong nc gang m thm vi vo. u im ca ch x lu l x c tnh oxy ha, kim v nhit cao, chy long tt, to x nhanh, x chy long tt, thun li cho vic kh P v S, tit kim c vi. - 79 -
X lu thng c dng khi gang c hm lng P va v cao.

c) Qu trnh thi luyn
Thnh phn nc gang dng cho l chuyn thi sn c thnh phn nh sau: %C 3,3 4,2 %Si 0,5 1,2 %Mn 0,5 1,0 %P 0,15 1,2 %S < 0,08
L chuyn trc khi nu c sy k. u tin than cc n 2/3 chiu cao l, t than nung l n sng trng, sau co ht than ra, nc gang vo l, thi gi, dng l v v tr thi v bt u qu trnh thi luyn. Qu trnh bin i thnh phn nc gang thanh thp th hin trn hnh 6.4.
Gc thi Cht liu im cui Ra thp Kh oxy FeO CaO SiO2 P2O5 MgO MnO C S P Si
5 4 3 2 1 0
CaO, SiO2, MnO, MgO, P2O5, FeO (%)
P, S . 10-2(%)
Mn, Si(%)
0,6 0,5 0,4 0,3 0,2 0,1
1,4 1,2 1,0 0,8 0,6 0,4 0,2
C(%)
40 35 30 25 20 15 10 5 0
3,4 3,2 2,8 2,4 2,0 1,6 1,2 0,8 0,4
Mn
Co x
8 10 12 14 16 18 20 22 24
Hnh 6.4 Thay i thnh phn kim loi v x trong l chuyn thi sn bazzic
Qu trnh thi luyn c th chia ra hai thi k: + Thi k u: Fe, sau l Si, Mn b oxy ha, i khi P cng b oxy ha. Cc phn ng: - 80 -
2[Fe] + 2[O] = 2[FeO] + 128.800 kcal

2[FeO] + [Si ] = 2[Fe] + (SiO 2 ) + 78.900 kcal
Kt hp hai phn ng trn ta c phn ng:
[Si] + 2[O] = (SiO ) + 207.850

2
kcal
Mi kilgam Si chy cho ta 7.420 kcal, lng nhit ny c th tng nhit 100 kg liu t 1300oC ln thm 172oC nn nhit nc thp tng rt nhanh. Phn ng t chy Mn:
[Mn ] + [FeO] = [F]e + (MnO ) + 31.290
kcal
Hiu ng nhit ca phn ng oxy ha Mn tng i nh ch b lng nhit do gi mang i nn t nh hng n nhit nc thp. Cc oxyt cng tham gia phn ng to x:
2(FeO) + (SiO 2 ) = (2FeO.SiO 2 ) + 1.130 kcal
(Feo) + (SiO 2 ) = (FeO.SiO 2 ) + 5.900
kcal
MnO + SiO 2 + MnO.SiO 2 + 7.000 kcal
Trong giai on ny sau t pht ta thy khi nu bay ra, sau l nng ht mu xm (ht x cha SiO2). Do hiu ng nhit ch yu ca phn ng oxy ha Si v mt phn ca cc phn ng khc nhit ca l tng nhanh, khi nhit l > 1470oC th c ngn la sng (cacbon bt u chy), th nghing l, ngng gi tin hnh co x c v to x mi ri chuyn sang giai on th 2. + Thi k th 2: trong giai on ny C v P ng thi b oxy ha, phn ng oxy ha P v C nh sau:
2[Fe 2 P ] + 5(FeO) + 4(CaO ) = (4CaO.P2 O 5 ) + 9[Fe] + 130.000 kcal
Phn ng oxy ha P ta ra lng nhit kh ln c tc dng lm tng nhanh nhit nc thp. Ni chung trong giai on ny P b kh ti mc yu cu, thng khng phi thi thm kh P. Phn ng ch yu trong giai on ny l phn ng chy C:
[C] + {O } = {CO } + 97.650

2 2
kcal
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[C] + 1 {O } = {CO} + 29.970

2
2
kcal kcal kcal
{CO} + 1 {O 2 } = {CO 2 } + 67.630

2
[FeO] + [C] = [Fe] + {CO} 34.460

ming l ta thy c ngn la di v sng.
Do c phn ng chy cacbon to thnh CO ri tip theo chy thnh CO2 m Thng ngi ta cn c vo ngn la v tnh hnh phun bn x phn on v iu chnh qu trnh thi luyn. Nu ngn la di, mnh v sng th nhit tt, nu ngn la yu, vng th nhit thp cn c bin php x l kp thi. i vi x, nu ht x bn ra u v ht nh th tt, nu x bn ra tng mng chng t x c cn iu chnh. Khi ngn la bt u thu ngn li, nhng ht thp khng phn nhnh v to tia la na, chng t %C xung thp, th ngng thi gi tin hnh kh oxy v ra thp. Kh oxy c tin hnh s b trong l, sau ra thp v kh oxy ngoi l. Cht kh oxy s b l nhm di dng fernhm (lng dng 0,3 0,7 kg/tn thp) hoc gang lng sch (vi lng dng 30 50 kg/tn thp). Cht kh oxy ln cui l fermagan, fersilic v nhm sch (lng dng 0,3 0,7 kg/tn thp). d) Cc bin php k thut nhm nng cao cht lng nc thp Nhit nc thp: qua phn tch trn ta thy cn bng nhit ca l thi sn khng thiu nhng nu khng tn dng ht ngun nhit c th dn ti thiu nhit v gy ngui l. Bng 6.3 cho thy nh hng ca cc yu t trong qu trnh nu luyn ti nhit nc thp ti im cui qu trnh. Bng 6.3 Cc yu t nh hng n nhit thp lng Yu t nh hng Nhit gang lng Nhit gi Cc bon oxy ha * tng nhit cho 100 kg nc gang 10oC 10oC 0,1 kg - 82 Bin i thnh nhit lng c ch (kcal) + 143,4 + 61,0 + 208,0 Bin i nhit nc thp + oC - oC 7,81 3,32 11,33
Phtpho oxy ha Silic oxy ha St oxy ha Vi** Vy sy Thp vn CO2 trong vi m ca gi Ko di thi gian luyn*** Ko di thi gian ngoi l Ghi ch: *
0,1 kg 0,1 kg 0,1 kg 1,0 kg 1,0 kg 1,0 kg 1,0 kg 18g/m3 1 ph 1 ph
+ 397,0 + 346,0 + 48,3 - 288,0 - 610,0 - 238,0 - 81,5 - 64,1 - 111,0 - 70,0
21,70 18,90 2,63 15,7 33,0 12,8 4,45 3,50 6,0 4,0
Cc bon chy thnh CO: 37,5%, CO2: 62,5%.
** Vi kh khi nung th tch gim 2,793 %. *** tnh tiu chun l 21 pht. Qua bng trn ta thy cc gii php nng nhit nc thp l: + Nng nhit nc gang: yu cu nhit nc gang t 1280 1350oC, nu nng ln > 1400oC c th gim %Si v rt ngn thi gian thi luyn. + Chn thnh phn nc gang thch hp, thng chn nh sau: % (Si + P) = 1,4 1,6 % %C = 3 ,6 4,2 % %Mn = 0,4 0,6 % %S < 0,08 % + Tng tc thi luyn, rt ngn thi gian ch nc gang. + m bo kim thch hp, gim bt lng vi khng cn thit, vi cn nung chn v gi tht kh. Kh P v S: trong l chuyn thi sn bazic, vic kh P tin hnh nh x, phn ng kh:
2[Fe 2 P ] + 5(FeO ) + 4(CaO ) = (4CaO.P2 O 5 ) + 9[Fe] + 130.000 kcal
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iu kin kh P tt l kim phi cao, hm lng oxyt st cao v nhit thp, do tt nht l kh P ngay giai on u. Trong l chuyn thi sn baz, vic kh S tin hnh nh x v kh ha kh S. iu kin kh S bng x c hiu qu l: baz ca x cao, hm lng oxyt st trong x thp, nhit cao, trong vai tr ca baz rt ln. Khi kh S bng kh ha, xt v mt nhit ng hc ch c th tin hnh qua x:
[S ] + 3 {O } = (O ) + {SO } 2
2 2 2 2
6[F +3 ] + (S 2 ) + 2(O 2 ) = 6(Fe +3 ) + {SO 2 }
Bi vy kh S bng kh ha yu cu x phi c tnh linh ng tt. Kh nng kh S ca l thi sn baz kh cao, khong 40 60 %, tuy nhin nu %S trong gang qu cao th sau khi thi luyn vn c th vt qu gii hn cho php, v vy %S nn chn trong khong 0,05 0,08%. Gim tn tht do thi luyn v phun bn: tn tht kim loi trong l thi sn baz rt ln, c th chia ra hai loi: tn tht ha hc, tn tht c hc. Tn tht ha hc chim khong 2/3 tng tn tht, ch yu l do cc tp cht nh Si, Mn, P, S v Fe b oxy ha, trong cn hn ch oxy ha st qu mc bng cch tng cng s khuy trn ni l, trnh hin tng thi treo. Tn tht c hc gy ra do nhng ht kim loi b ln ln trong x, b cun theo khi l v c bit l do phun bn ra ngoi, nht l thi k th hai khi cacbon chy. gim phun bn cn chn ch gi thch hp, phn ng kh C ng lc v hn ch x bng cc bin php sau: + Chn ch gi thch hp, bo m ni l khuy trn tt; + Dng nc gang cha %Si thp, nhit cao, m bo nhit kh C; + Dng x kp, co bt x axit ban u; + Thi chm hp l h thp FeO; + X bt gi khi xy ra phun bn; + m bo dung tch lng l ln.
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Cht lng thp: cht lng thp l chuyn khng c cao, ch yu do tp cht phi kim: + Nit : nit tng nhy cm ha gi ca thp, hm lng nit trong thp ph thuc su thi luyn, su thi luyn cng ln, %N trong thp cng ln. gim %N cn phi duy tr tt ch thi mt. Hyr: hyr trong thp l thi sn tng i thp ( 2,5 3,5 ml/100g) nn t quan tm. + Oxy: lng oxy trong thp cng cao khi %C cn li trong thp cng ln, mun gim hm lng oxy trong thp th phi ht sc trnh thi thm hoc thi treo vo cui thi k nu luyn. + Tp cht: tp cht trong thp l thi sn ch yu l sn phm qu trnh kh oxy. Nhit nc thp trong l thi sn thp nn rt kh kh tp cht, do vy mun kh tp cht cn nng cao nhit nc thp, mt bin php khc l tin hnh kh oxy s b trong l.
6.2.3. Cng ngh luyn thp trong l thi sn axit a) c im
Trong sn xut thp, l thi sn axit c nhiu nc s dng,do c u im: + Hiu ng nhit cao, nhit nc thp cao; + Tng l bn; + Nng sut cao; + Thao tc d, khng i hi cng nhn c tay ngh cao; + Vn du t thp v thi gian xy dng nhanh; Nhng l axit c nhc im: + Ch luyn c thp t gang c P v S thp; + Chy hao kim loi ln. Trong iu kin nc ta, gang thng c hm lng P, S cao, trong khi vic u t cc thit b kh P, S ngoi l kh thc hin nn kh nng s dng l chuyn thi sn axit rt t c trin vng.
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b) Quy trnh thi luyn
Qu trnh thi luyn trong l thi sn axit c th chia lm hai giai on: Giai on u: khi nhit l cha cao, st b oxy ha, sau Si, Mn b oxy ha mnh lit. Do hiu ng nhit ca phn ng oxy ha (ch yu l oxy ha Si) nhit l tng ln nhanh chng. Quan st ming l ta thy: sau khi thi 1 2 pht c khi nu bay ra bo hiu s oxy ha st, sau khong 6 8 pht xut hin ngn la lc u sm sau sng bo hiu cacbon bt u chy. Giai on hai: do nhit l tng cao nn ch yu l chy cacbon, quan st ming l ta thy ngn la sng, di (c th ti 3 4 mt). Khi ngn la li dn bo hiu cacbon chy n gii hn yu cu th ngng gi tin hnh kh oxy. Kh oxy ln u s dng fermangan 70 cho vo ni rt (lng dng 5 kg/1 tn thp), tip theo dng fersilic 45 kh tip (lng dng 5 kg/1 tn thp) v kh oxy ln cui bng nhm. Nu sn xut thp hp kim th th t cho vo l nh sau: Ni, Cu cho vo l cng vi nc gang, Cr, V, Mg v cc nguyn t d b oxy ha khc th cho vo thng rt.
6.3. Luyn thp trong l LD 6.3.1. Cu to l
S cu to l LD trnh by trn hnh 6.5. B phn l gm ba phn: y l hnh chm cu (1), tng l hnh tr (2) v ming l hnh cn vt (3). V l ch to bng thp tm hn hoc tn riv, ton b l t trn gi (6) v c th quay quanh trc nm ngang nh c cu quay l (5). Thn l to khng gian cng tc, gm lp gch cng tc xy bng gch manhzit, lp gch cch nhit. Mi l dng nh hng kh chuyn ng ca kh thi, trn mi l c b tr l ra thp. quay l c th dng c cu quay c kh hoc thy lc.
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2 B 6
A Lp gch cng tc V thp Lp gch cch nhit
B Lp m Lp gch cng tc V thp
Hnh 6.5 S cu to l LD 1) y l 2) Thn l 3) Mi l 4) Thit b thi oxy 5) C cu quay l 6) Gi
B phn thi oxy c cu to nh hnh 6.6, gm ng thi oxy (1), o nc lm ngui (2) v u vi phun (3). u vi phun (3) c prfin dng ng venturi cho php tc dng kh phun ra t tc siu m.
O2
. . .
H2O H2O
3 Hnh 6.6 Cu to ng thi xy 1) ng thi 2) o nc 3) u phun
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6.3.2. Quy trnh luyn thp trong l LD
Quy trnh luyn thp trong l LD gm cc giai on: + Np liu; + Oxy ha; + Kh oxy; + Ra thp. a) Np liu: np gang lng, np cht to x vo l. b) Giai on oxy ha: Sau khi np gang lng, a ng thi oxy i xung cch mt kim loi khong 450 800 mm v tin hnh thi oxy vo l. p sut ca kh oxy t 6 7 atm, lng tiu th khong 8 10 lt/giy. u tin l Si , tip theo l Mn b chy rt nhanh, ri C v P ng thi, sau cng l S.
P, S . 10-2(%) Mn, Si(%) C(%)
0,6 0,5 0,4 0,3 0,2 0,1
1,4 1,2 1,0 0,8 0,6 0,4 0,2
3,4 3,2 2,8 2,4 2,0 1,6 1,2 0,8 0,4
C S P Si
Mn
8 10 12 14 16 18 20
Hnh 6.7 Thay i thnh phn kim loi trong l LD
Trong qu trnh thi luyn, tc oxy ha cc tp cht xy ra rt nhanh, nn nhit kim loi tng rt nhanh, gim nhit ngi ta c th cho thm thp ph vo l.
c) Kh oxy v hp kim ha
kh oxy dng phng php kh lng, do khng to c mi trng hon nguyn nn khng th dng phng php kh khuch tn. Khi nu thp hp kim, sau khi kh oxy tin hnh pha cc nguyn t hp kim. d) Ra thp: di chuyn ng thi ra khi l, tin hnh quay nghing l ra thp.
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- 89 -
Chng VII
LUYN THP TRONG L MACTANH

7.1. c im Phng php luyn thp trong l mactanh (hay cn gi l l bng) c s dng rng ri trong cc nc cng nghip pht trin. u im ca luyn thp trong l mactanh l: + S dng c nhiu loi nguyn liu kim loi ( gang thi, thp vn v gang lng); + S dng ngun nhit bn ngoi nn ch ng v cn bng nhit; + Luyn c nhiu loi thp vi cht lng tt; + Dung tch l ln, p ng c nhu cu sn lng ln. Nhc im: + Kh l tham gia vo cc phn ng ha hc lm kim loi b oxy ha. Do hn ch kh nng nu cc thp hp kim; + Vn u t ln, thi gian thi cng v xy dng di; + Chi ph sn xut ln. 7.2. Thit b 7.2.1. Cu to Ttrn hnh 7.1 trnh by s cu to ca l mactanh. Cc b phn c bn ca l gm: + Bung l (b luyn); + H thng knh dn khng kh v kh t (ng thi l h thng thot kh thi); + Thit b hon nhit nung nng khng kh v kh t; + Van i chiu khng kh v kh t; + Khung l. 7.2.2. Nguyn l lm vic L bng lm vic theo ch hot ng chu k. Sau khi np liu xong, m van i chiu (17) v (18) dn khng kh v kh t theo cc knh dn bn tri qua cc bung hon nhit (3), (4) c nung nng. Sau khi c nung nng ti nhit
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1100 1300oC, khng kh v kh t tip tc i vo u l bn tri, phun vo bung luyn v b t chy, to thnh ngn la. Sau khi truyn nhit cho kim loi, khi l theo cc knh dn u l bn phi, i qua cc bung trao i nhit (11) v (12) nung nng gch trong bung hon nhit v tip tc qua van i chiu (17), (18) tp trung v cng khi (15) v ti ng khi (16) thi ra mi trng.
6 500 C 16
o
7 1700oC
Sn thao tc Khng kh
19 4 3 2 1 18 13 17 11 12 14 900oC 1400oC 1350oC
10
550oC
15
400oC
Kh t
Hnh 7.1 S cu to l bng 1,13) Cng khng kh 2,14) Cng kh t 3,11) Bung hon nhit khng kh 4,12) Bung hon nhit kh t 5,10) Knh ng 6, 9) u l 7) Bung luyn 8) Ca cht liu 15) Cng khi 16) ng khi 17) Van i chiu khng kh 18) Van i chiu kh t 19) Bung lng x
Sau mt thi gian nht nh khi nhit bung trao i nhit (3), (4) bn tri ngui xung di mc quy nh v bung trao i nhit bn phi c nung nng , tin hnh o chiu van (17) v (18) dn khng kh v kh t vo bung luyn qua cc knh bn phi, lc ny cc knh bn tri ng vai tr knh dn khi. Tip tc lp li chu trnh cho n khi kt thc nu luyn. Hin nay a s cc l mactanh cng vic iu chnh ch nhit u c t ng ha.
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7.3. Cng ngh nu thp trong l mactanh 7.3.1. Nu thp trong l mactanh baz a) Nguyn, nhin, vt liu: nguyn vt liu luyn thp trong l mactanh baz gm: nguyn liu kim loi th rn hoc th lng, cht oxy ha, cht to x, cht kh oxy. Nguyn liu kim loi: thp ph, gang thi v cc loi fer hp kim. Nhin liu: kh t hoc du. Cht to x: vi, hunh thch. Cht oxy ha: qung st, vy st. b) Quy trnh nu luyn Giai on nu chy: sau khi np liu, iu chnh van cp kh t v khng kh vo l t chy thnh ngn la cp nhit cho l. Kim loi trong l c nung nng, sau chy lng dn v tp trung xung y b luyn. tng tc nu chy, ngn la thng c hng v pha b mt kim loi trong b luyn (ch truyn nhit trc tip). Trong giai on nu chy Si hu nh b oxy ha hon ton, cn Mn v P ch b oxy ha mt phn. Khi kim loi trong b luyn hnh thnh, tin hnh cho vi v cc cht to x vo l to x. Sau khi nng chy xong, baz ca x vo khong 1,7 2,2. Giai on oxy ha: nng nhit nc thp ln trn 1560oC v tin hnh cho qung vo tip tc oxy ha cc tp cht v kh P, lng qung cho vo phi > 0,5% trng lng nc thp. Trong giai on ny phn ng oxy ha cacbon l phn ng ch yu xy ra trong l, tc kh C khi nu thp cacbon thng 0,35%/pht khi si qung v khong 0,15 0,35% khi si sch.
-
Giai on kh oxy s b: kh oxy s b dng fersilic cho trc tip vo l, Pha nguyn t hp kim: cc ferniken, fermlipen, fervnfram cho vo
lng dng tnh theo 0,15% trng lng thp lng. trc giai on tinh luyn v trc khi kh oxy khong 20 pht phi iu chnh xong thnh phn. Fercrm cho vo sau khi kh oxy s b, khi hm lng fercrm trn
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2% th nn cho vo l lm hai ba t, mi t cch nhau khong 5 pht, m fercrm cho vo sau cng phi gi li trong l t nht l 15 pht. Kh oxy v hp kim ha trong thng rt: cc loi fer dng kh oxy v hp kim ha trong thng rt gm c: fersilic, fertitan, fervanai, siliccanxi. 7.3.2. Nu thp trong l mactanh axit Khc vi l mactanh baz, kh nng oxy ha ca x trong l mactanh axit thp, do nng ca oxy trong thp rt thp, ng thi khng c kh nng kh P v S. Bi vy, nguyn liu phi sch v P v S (P 0,03%, S 0,03%) v nhin liu phi sch v S. Quy trnh nu luyn gm cc giai on: Np liu: c th np liu ngui (khi dng mt l) hoc np liu nng (khi dng hai l). Khi np liu ngui, nguyn liu kim loi c cht vo l qua ca cht liu bn hng bung luyn. Khi np liu nng (dng hai l), u tin thp c nu bng liu ngui trong l th nht (l baz), sau rt thp lng bn thnh phm vo l th hai (l axit) c nung nng trc, thi gian nung trc t 4 6 gi. Trc khi rt thp lng vo (trc khong 40 90 pht), phi cho cht to x vo bung luyn. Giai on nu chy: tin hnh nu chy gang v thp vn. Giai on oxy ha: t chy cc tp cht Si, Mn v C. Ngi ta p dng hai phng php luyn trong l axit: phng php hon nguyn Si (phng php th ng) v phng php hn ch hon nguyn Si (phng php ch ng). Phng php hon nguyn Si l phng php m khi luyn c s hon nguyn Si t x v t y l (y l thng m bng cct thch anh c thnh phn 97,4% SiO2). Khi luyn thp si, nhiu khi lng Si hon nguyn kh oxy trong thp m khng cn cho thm cht kh oxy. c im ca phng php ny thch hp vi cc loi thp cacbon va. Khi luyn thp cacbon cao, do nhit luyn thp tng i thp nn Si kh hon nguyn, cho nn khi cacbon t yu cu th Si vn thiu. Ngc li, khi luyn thp cacbon thp, nhit luyn tng i cao, Si hon nguyn qu nhanh, lm cho nc thp t
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kh oxy, dn n cacbon kh b kh, thm ch khng th gim cacbon n mc quy nh. Khi luyn theo phng php hon nguyn Si, do nhit l kh cao nn Mn cng c hon nguyn, trc khi kh oxy, hm lng Mn 0,28%. Do vy, khi luyn theo phng php ny, lng Si v Mn kh oxy, khng cn thm cht kh oxy hoc dng rt t, nh cht lng thp s cao v t ln tp cht do cht kh oxy mang vo. Phng php hn ch hon nguyn silic: trong qu trnh nu luyn, ch ng hn ch s hon nguyn ca Si bng cch thng xuyn cho qung hoc vy st vo l nng cao kh nng oxy ha v gim nhit ca x, hoc bng cch cho vi vo gim lng SiO2 trong x. Lng Si hon nguyn ch t 0,10 0,12% v trc khi kh oxy lng Si thng khng vt qu 0,17%. c im ca phng php ny l c th luyn c tt c cc loi thp cacbon thp, va v cao.
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- 94 -
Chng VIII
C PHI THP
8.1. Phn loi v c im c phi l mt khu quan trng trong quy trnh sn xut thp cn. Cht lng phi c nh hng ln n cht lng ca sn phm cn cng nh nhiu ch tiu kinh t, k thut khc. Ty thuc quy m sn xut v vn u t, c th s dng phng php c phi bng khun hoc c lin tc. Trong phng php c khun (hay cn gi l c tnh), thp lng c rt vo khun nh hnh, ngui v ng c to thnh thi c kch thc v hnh dng theo yu cu. Hnh dng v kch thc thi c ph thuc hnh dng v kch thc ca lng khun. c im ca c khun l vn u t thp, nhng nng sut thp, t l hao ph kim loi ln, thng c ng dng khi sn lng nh v va. Trong phng php c lin tc, thp lng c rt lin tc vo thng kt tinh c lm ngui bng nc, trong thng kt tinh thp lng ngui nhanh v ng c to thnh thi v c ko ra khi thng kt tinh mt cch lin tc trong sut qu trnh c. Tit din ngang ca phi c ph thuc hnh dng tit din ngang ca lng thng kt tinh, chiu di phi khng hn ch. c im ca phng php l nng sut cao, cht lng phi tt, nhng vn u t ln, ch ph hp khi sn lng ln. 8.2. L thuyt v qu trnh kt tinh Qu trnh kt tinh ca phi c l qu trnh vt l phc tp, hiu r qu trnh kt tinh cho php ta tc ng vo qu trnh hnh thnh phi, t c cu trc kim loi theo mong mun v hn ch cc khuyt tt c th xy ra. Nh chng ta bit, s kt tinh ca thp lng cng nh kim loi ni chung, gm hai qu trnh xy ra ng thi: + Qu trnh to mm kt tinh: mm t sinh hoc mm c sn, l cc tinh th xut hin ban u c kch thc ln hn hoc bng mt kch thc ti hn c th tip tc pht trin (ln ln) thnh ht tinh th. + Qu trnh pht trin tinh th: tinh th tip tc ln ln v to thnh ht tinh th. - 94 -
Trong qu trnh thp lng kt tinh, thng xy ra nhiu hin tng lin quan n s hnh thnh phi c nh: co ngt, ha tan v tit kh, thin tch ... nh hng ln n cht lng phi. 8.2.1. iu kin hnh thnh v ln ln ca tinh th Trong qu trnh kt tinh th nng lng t do ca h s gim, tc l G < 0 . Gi f l bin thin nng lng t do khi mt n v th tch kim loi kt tinh qu ngui T , ta xc nh c gim nng lng t do ca h do qu trnh kt tinh mt th tch V gy ra:
G V = f .V Trong :
G V - bin thin nng lng t do khi kt tinh;
V - th tch kim loi kt tinh;

f - bin thin nng lng t do n v.
Mt khc, khi tinh th hnh thnh b mt tinh th c din tch S c to ra, nng lng b mt xc nh bi cng thc:
G S = .S
Tng bin thin nng lng ca h:

G = G V + G S = f .V + .S
(8.1)
Gi s tinh th c dng hnh cu bn knh r, th th tch (V) v din tch b mt (S) ca n l:

3 V = .r 3 4
S = 4r 2
Thay vo cng thc (8.1), ta c:

3 G = .r 3 + .4r 2 4 Biu din G V , G S v G trn th ta c hnh 8.1.
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G GS G
rk
r
GV
Hnh 8.1 Bin thin nng lng t do ca h khi kt tinh
T th ta nhn thy, vi r < rk khi tinh th pht trin (ln ln) th nng lng ca h tng do qu trnh khng th tip tc. Ngc li vi r rk th khi tinh th pht trin th nng lng ca h gim do qu trnh c th tip tc. Ngi ta gi rk l kch thc ti hn ca mm tinh th, gi tr ca n xc nh bi biu thc:
rk = 2 f
(8.2)
Vy iu kin mm tinh th ln ln l phi c kch thc ban u ln hn kch thc ti hn. Kch thc ti hn ca mm ph thuc vo sc cng b mt gia pha rn (tinh th) v pha lng (kim loi lng) v bin thin nng lng n v f tc l ph thuc vo qu ngui T. Hnh 8.2 biu din s ph thuc ca bn knh tinh th gii hn ng vi cc nhit qu ngui khc nhau (T1 <T2 <T3), ta thy khi qu ngui cng ln th kch thc tinh th ti hn cng nh (rk1 < rk2 <rk3).
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T1<T2<T3 T3 T1 T2
rk1 rk2 rk3
Hnh 8.2 S ph thuc ca bn knh tinh th gii hn vo nhit qu ngui
8.2.2. Qu trnh kt tinh v ta nhit
Khi thp lng ngui t nhit rt (Tr) n nhit kt tinh (T0) v kt tinh, sau ngui n nhit phng (Tf), th nhit lng ta ra l:
Q = C p ( L ) (Tr T0 ) + L kt + C p (S) (T0 Tf ) Q = Q 3 + Q 2 + Q1
Hay Trong :
Cp(L) - nhit dung ca thp trng thi lng; Cp(S) - nhit dung ca thp trng thi rn; Q3 - lng nhit qu nhit; Q2 - lng nhit kt tinh; Q1 - lng nhit ngui. Bng 8.1 cho lng nhit ta khi c mt s loi phi thp. Bng 8.1 Lng nhit ta khi c mt s loi phi thp Mc thp C20 St do (Fe) Lng nhit ta (j/g) Q1 962,54 1056,08 Q2 329,56 276,33 Q3 18,09 24,12
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Khi c khun th lng nhit ta ra t lc rt cho n lc thp ng c hon ton (truyn qua thnh khun v khng kh) vo khong 502,4 628,0 kj/kg, cn khi c lin tc vo khong 460,5 502,4 kj/kg, trong truyn nhit qua thng kt tinh khong 160,5 170,0 kj/kg, trong khu vc lm ngui ln th hai khong 230,3 251,2 kj/kg.
8.2.3. Qu trnh kt tinh v co ngt th tch
Khi ngui v kt tinh, th tch thp lng gim, ngi ta gi hin tng l co ngt. Tng th tch co ngt ca thp khi ngui v kt tinh xc nh bi cng thc:
V = Vl + Vkt + Vr
Trong :
V - tng th tch co ngt; Vl - th tch co ngt trng thi lng; Vkt - th tch co ngt khi kt tinh; Vr - th tch co ngt trng thi rn.
co ngt ca thp ph thuc vo nhit rt, thnh phn ha hc ca thp (xem bng 8.2 v 8.3). Bng 8.2 co ca thp ph thuc hm lng cacbon [C] 0 0,1 0,2 0,3 0,4 0,5
Vl Vkt Vr V
(%/100oC) 1,51 1,50 1,5 1,59 1,59 1,62
(%) 1,98 3,12 3,34 3,72 4,03 4,13
(%) 3,49 4,62 4,89 5,31 5,62 5,75
(%)
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Bng 8.3 co ca thp ph thuc hm lng nguyn t hp kim Hp kim Ni Mn Si Cr W Hm lng (%) 9,44 8,5 3,6 13,7 2,5
Vl Vkt Vr V
(%/100oC) 0,25 2,28 2,05 1,66 1,39
(%) 3,40 0,44 1,77 0,90 3,20
(%) 6,07 6,15 5,95 6,14 6,44
(%) 9,72 8,87 9,77 8,70 11,03
T bng 8.2 v 8.3 ta nhn thy co ngt ca thp trng thi lng khng ln ( 1%), nhng khi chuyn trng thi kh ln ( 4%) v khi trng thi rn t ti 7 8%.
8.2.4. Qu trnh kt tinh v thin tch
Thin tch l hin tng khng ng nht v thnh phn ha hc trong mt vng hoc ton khi kim loi kt tinh (thi thp hoc phi c). Do khng ng nht v thnh phn ha hc, c tnh ca thp trong vng hoc trong khi thp s khc nhau do nh hng n tnh nng s dng ca thp. nh gi mc thin tch ngi ta a ra cc khi nim: + thin tch:
+ H s kt tinh la chn: A= C i max C i min
K=
C il C ir Ci(l) Ci( r ) Ci(r) .100 [%]
+ T l thin tch
%C i =
Nguyn nhn gy ra thin tch c th do s kt tinh c chn lc hoc do s phn ly theo trng lng. Khi kt tinh c chn lc, thnh phn c nhit kt tinh cao kt tinh trc, thnh phn c nhit kt tinh thp kt tinh sau. Khi phn ly theo trng lng, thnh phn nng chm xung cn thnh phn nh th ni ln. Cn c vo phm vi thin tch ngi ta chia thin tch ra hai dng:
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+ Thin tch vi m: xy ra trong phm vi mt tinh th. + Thin tch v m: xy ra trong phm vi mt vng hoc ton khi. Thin tch vi m xy ra do s kt tinh c chn lc v tc khuch tn hn ch, dn n thn tinh th giu thnh phn kh chy, bin tinh th giu thnh phn d chy (thng l tp cht). Thin tch vi m c th khc phc bng cch khuch tn lm ng u thnh phn. Thin tch vng xy ra do s kt tinh c chn lc hoc do phn ly trng lng. Thng thng thi thp c lm ngui t ngoi vo trong, cc thnh phn c nhit chy thp v nh hn b y dn vo trong v ni ln to thnh vng thin tch.
8.3. Thit b v cng ngh c khun 8.3.1. Khun c a) Phn loi
Khun c l thit b chnh khi c thp thi, theo phng php rt ngi ta chia ra: + Khun c di (xi phng). + Khun c trn.
a)
b)
Hnh 8.3 Phn loi khun c thi a) Khun c di b) Khun c trn
c di dng h thng rt xi phng, dng chy kim loi vo khun m, cht lng b mt thi tt, ng thi mi ln rt c th c ng thi nhiu thi nn nng sut cao, nhng tn kim loi cho h thng rt ( khong 6 7%). c trn mi ln c ch c c mt thi, ng thi do kim loi rt t trn xung y khun chng hng v kim loi b bn te nn cht lng b mt thi xu hn c c di. - 100 -
b) Cu to khun
Khun c thi chia lm hai loi khun c thp lng v khun c thp si. Khun c thp lng c dng trn to, di nh, tit din ngang l hnh trn, vung hoc ch nht c ch to t gang c chu nhit hoc gang cu.
a)
b)
Hnh 8.4 Cu to khun c thp lng a) Khun khng y b) Khun c y 1) Khun thi 2) Tay khun 3) M gi nhit
Khun c thp lng c th khng c y (hnh 8.4a) hoc khng c y (hnh 8.4b). Khi c thp lng, khun c thng c m gi nhit, cu to gm mt lp v thp bc ngoi, bn trong xy gch cch nhit. Khi kim loi kt tinh phn di c lm ngui nhanh kt tinh trc, phn trn ngui chm kt tinh sau c tc dng b co cho phn di. Khun c thi thp si c dng trn nh, di to, tit din ngang tng t khun c thp si nhng thng nh hn.
Hnh 8.5 Cu to khun c thp si
- 101 -
c) ng rt trung tm
Khi rt di ngi ta dng ng rt chung gia gi l ng rt trung tm, c cu to nh hnh 8.6.

1
2 2 6 3 4 5 4 3
Hnh 8.6 ng rt trung gian 1) Gch phu 2) Gch ng rt 3) Gch phn nhnh 4) Gch cng rt 5) Ct chn 6) Thnh ng rt bng gang
d) a c
a c dng lp t h thng rt v khun c thi, c ch to bng gang c dng ngh hnh 8.7
.
Hnh 8.7 a c
- 102 -
8.3.2. Cu trc thi thp a) Cu trc thi thp lng
Cu trc tinh th: Rt kim loi vo khun, lp kim loi lng tip xc trc tip vi thnh khun c lm ngui rt nhanh, kim loi chu mt qu ngui ln, ng thi b mt nhm ca thnh khun to nn nhng tm mm kt tinh c sn nn tc kt tinh rt ln, to ra lp tinh th nh mn, ng trc, v hng.
6 5
1 2 3 4
b)
a)
c)
Hnh 8.8 Cu trc thi thp lng a) S cu trc b) Giai on kt tinh lp ngoi c) Giai on kt tinh nhnh cy 1) Lp tinh th nh mn 2) Lp tinh th hnh tr 3) Vng tinh th ng trc 4) Vng tinh th y 5) L co 6) Vng tinh th th i
Tip theo, nhit thnh khun tng ln, ng thi s truyn nhit t lp trong ra ngoi i qua lp tinh th mi kt tinh nhit cn rt cao, tc truyn nhit gim xung, kim loi chu mt qu nhit khng ln nh ban u nn tinh th hnh thnh chm hn v pht trin theo hng vung gc vi thnh khun, to thnh vng tinh th hnh tr (hay cn gi l tinh th nhnh cy). Khi ton b kim loi lng cha kt tinh pha trong t n qu ngui cn thit v kt tinh ng thi, hnh thnh nn vng tinh th ng trc v hng th i (kch thc tinh th ln hn nhiu so vi kch thc tinh th lp ngoi cng). Ngoi ra, do truyn nhit qua y khun (a c), y thi hnh thnh mt vng tinh th nh mn hnh chp, cn vng m nhit do tc ngui chm, kim loi - 103 -
kt tinh sau cng, mt phn kim loi b co cho phn th tch kt tinh trc to thnh l co, phn cn li kt tinh to thnh vng tinh th xp bao quanh l co. Thin tch: trong thi thp c thng thy r nht l thin tch ca S, P v C. Lp tinh th nh mn ngoi cng do kt tinh nhanh nn ng u v c th coi l vng khng c thin tch. Vng tinh th hnh tr, do kt tinh c chn lc v tc khuch tn hn ch, tm ht tinh th giu nguyn kh chy, bin gii ht giu nguyn d chy, to thnh thin tch nhnh cy (thin tch vi m). Thin tch vng trong vt c thp, thng thy r nht l s thin tch ca S, P. Khi nng ca cc tp cht nhiu hn mc trung bnh th s thin tch c gi l thin tch dng, ngc li gi l thin tch m. Trong qu trnh kt tinh cc tp cht nh S, P va b y dn t ngoi vo trong, va ni dn ln trn to nn thin tch hnh ch V ngc, vng pha trn tm thi do s dch chuyn ca kim loi b co hnh thnh nn thin tch hnh ch V thun. Dnh thin tch hnh ch V ngc v ch V thun l thin tch vng dng. pha di vng tm thi hnh thnh mt vng thin tch m, hm lng S, P thp hn mc trung bnh.
1 2
Hnh 8.9 Thin tch trong thi thp lng 1) Thin tch ch V ngc 2) Thin tch ch V thun 3) Thin tch m
Nh vy, thi thp lng thin tch nhiu nht l vng gia v vng pha trn. Nu thi cng ln th thi gian kt tinh cng lu, tp cht vng gia v vng pha trn cng ln. Mc thin tch vng ph thuc kch thc thi, t l gia b rng thi trn chiu cao cng ln th thin tch vng cng ln. - 104 -
Co ngt: do qu trnh kt tinh xy ra tun t t ngoi vo trong nn khi lp v rn hnh thnh, th tch kim loi lng pha trong tip tc ngui v kt tinh, th tch co li, kim loi lng pha trn chy xung b co, lm mc kim loi cn li h xung to thnh khong trng, tip tc nh vy dn dn hnh thnh l co c tit din hnh phu. Khi qu trnh kt tinh t n gn tm nhit, phn kim loi lng tm cn li t v chy long thp khng th chy xung b co li nhng l co kch thc b nm dc tm nhit gi l xp ng tm.
Hnh 8.10 L co trong thi thp lng
Th tch v hnh dng l co nh hng ln n sut thu hi kim loi, nu cng mt th tch m chiu cao l co cng ln th sut thu hi kim loi cng thp
b) Cu trc thi thp si
Cu trc tinh th: Cu trc tinh th ca thi thp si c ba vng r rt: lp tinh th nh mn mt ngoi, vng tinh th hnh tr v vng tinh th ng trc, v hng th i tm. Do trong thp si c xy ra phn ng oxy cacbon, kh CO thot ra to nn s xo trn mnh kim loi lng nn tinh th nhnh cy b cun gy, lm cho lp tinh th nh mn mt ngoi dy hn trong thi thp lng. Thin tch: thin tch trong thi thp si cng gm thin tch nhnh cy v thin tch vng. Thin tch vng, do kt tinh t ngoi vo trong v t y ln, nn tp cht va b y dn vo trong, va b y ln trn nn phn u ca thi tp trung nhiu tp cht.
- 105 -
Bt kh: lp tinh th nh mn ngoi cng do kt tinh nhanh nn st c v hu nh khng c bt kh. Sau khi hnh thnh lp v ngoi, cc bt kh to thnh gn ming khun (cch ming khun khong di 1/3 chiu cao thi) c th ni ln v thot ra ngoi, cc bt kh nm pha di rt kh ni ln nm li trong kim loi to thnh nhng r kh phn tn (r t ong). Do qu trnh kt tinh t ngoi vo v sau l t di ln, ng thi do cc bt kh ni ln, nn sau khi kt tinh hon ton phn u ca thi tp trung mt vng r kh gi l r xp.
3 1
Hnh 8.11 R kh trong thi thp si 1) R kh t ong 2) Bt kh ln 2 3) R xp tp trung
Do trong thi thp si hnh thnh cc bt kh b vo th tch co ngt nn trong thi thp si khng to thnh l co.
c) Cu trc thi thp na si
Qu trnh kt tinh v cu trc tinh th ca thi thp na si tng t thp si. Tuy nhin, do hn ch c s khuy trn ca CO nn cht lng cao hn thp si, ng thi c s to bt kh nn trong thi thp khng c l co, sut thu hi kim loi tng t thp si.
8.3.3. Cng ngh c khun a) Cng ngh c thp lng
Nhit rt: do nhit bt u v kt thc kt tinh ca mi mc thp l khc nhau nn cn xc nh nhit rt cho tng mc thp. Cng thc xc nh nhit rt cho mt mc thp c dng: - 106 -
t c = t Fe t i n i + t
Trong : tFe - nhit kt tinh ca st; ti - gim nhit khi thm vo 1% nguyn t tp cht (/1%); ni - hm lng nguyn t hp kim c trong thp (%); t - qu nhit (oC), thng chn 30 80oC. Bng 8.4 gim nhit ng vi 1% nguyn t tp cht Nguyn t C Si Mn P S ti 70 15 5 50 30 Nguyn t Cr Ni H N ti 5 2 40 50
m bo nhit c, nhit ra thp phi cao hn, m bo sao cho b gim nhit trong qu trnh t ra thp n khi rt xong: Tra thp = tc + tmt mt Trong : tmt mt = t 1 + t 2 + t 3 + t 4 t1 - gim nhit khi ra thp, vo khong 2 2,5 oC/pht; t2 - gim nhit khi vn chuyn, vo khong 1,5 2,0 oC/pht; t3 - gim nhit khi lng thp, vo khong 0,5 1,5 oC/pht; t4 - gim nhit khi rt thp , vo khong 1,0 oC/pht; Tc rt: xc nh bi lng kim loi rt vo khun trong mt n v thi gian (kg/s) hoc bi tc dng ca kim loi trong khun (cm/pht). Nu chn tc rt qu ln c th gy ra ph hng khun, gy bn te kim loi v ht kh, nhng nu chn qu thp c th lm cho kim loi in y khun khng tt hoc b mt thi b khp v gim nng sut. Thng chn tc rt theo s tay kinh nghim. - 107 -
Chun b thit b: cc nh my sn lng ln ( >500.000 tn/nm) khun c c lp rp trn xe gng v chuyn ti v tr rt, cn cc nh my v xng c sn lng b ( < 200.000 tn/nm) khun c c lp rp ngay trn nn xng. Vic lp rp khun tin hnh nh sau: + Bi khun: dng du bi khun (du cok) bi ln mt trong khun d tho khun v chng hnh thnh bt kh di lp v thi thp. Khi tip xc vi thp lng, du cok chy to ra kh CO hoc CO2 to thnh mng kh chng thi dnh bm vo thnh khun, ng thi kh CO hon nguyn oxyt st trn b mt thp lng chng s oxy ha mt ngoi thi. + Lp khun: khun c lp theo trnh t sau: u tin t a c, tin hnh lp gch cng rt, t gch phn dng, tip tc lp gch ng rt, phu rt, sau lp khun c thi v m gi nhit. Cui cng tin hnh kim tra v y np khun. chng m gy r kh, ton b thit b lun c duy tr nhit t 80 120oC. Thao tc c: tin hnh ra thp, dng thng rt vn chuyn n v tr c v ch lng thp. Khi ch thp lng, gim mt nhit c th dng cht che ph hoc tru, rm, r ... ri ln b mt thng rt. Sau khi thp ht si v ng u thnh phn th tin hnh rt khun. Thao tc rt khun yu cu phi chnh xc v m bo tc rt. Dng kim loi khi rt vo khun phi hng ng phu rt v khng c ngt qung. Khi thp lng dng ln n gn m gi nhit, gim bt tc rt b sung ngt v khi gn y m gi nhit ngt dng chnh xc trnh trn ra ngoi. hn ch mt nhit, khi rt gn ht dng cht pht nhit gm than cm, ht Al v ht fersilic ph ln mt. Sau khi rt, ch kim loi kt tinh xong th tho khun. Theo cng thc xc nh chiu dy lp kim loi kt tinh:
=K
Trong :
(8.1)
- chiu dy lp kt tinh (mm);

- thi gian kt tinh (pht); K - h s lm ngui ca thnh khun (mm/pht1/2). - 108 -
Vi phi trn, t cng thc (8.1) ta xc nh c thi gian kt tinh hon ton ca phi:
D = phi 2K
2
(8.2)
Trong : Dphi l ng knh ca phi. Thao tc tho khun tin hnh nh sau: u tin tho m gi nhit, sau dng thit b tho khun tng thi ra khi khun, kim tra cht lng b mt ca thi v vn chuyn ti l nung hoc ch ngui hn chuyn ti kho cha. Sau khi tho phi, khun c a tr li v tr c v tin hnh lp rp tip tc c ln khc.
b) Cng ngh c thp si
Cng ngh c thp si tng t c thp lng, nhng trong qu trnh c cn lu cc vn sau: + Tc rt chm hn khi c thp lng to iu kin cho kh CO thot ra. + hn ch s thin tch, sau khi rt xong dng nc di ln xung quanh ming khun hoc dng np gang y kn ming khun. Lm ngui ming khun nhm to ra lp v c trn mt (hoc y khun), khi phn ng oxy ha cacbon xy ra do CO khng thot c ra ngoi, to nn p lc ln khng cho CO tip tc thot ln, ngn phn ng tip tc xy ra.
8.4. c lin tc
c lin tc l phng php c c nhiu u im: + Nng sut cao v c th cp phi lin tc cho phn xng cn; + c trc tip ra phi nn khng cn qua khu cn ph; + Hiu sut thu hi kim loi ln (do khng cn h thng rt, b ngt ...), hiu sut thu hi thng trn 95 96%; + Tc kt tinh ca kim loi nhanh, t chc kim loi st c; + Cht lng thp v cht lng b mt phi tt, thin tch t; + Gim din tch mt bng sn xut; + D c kh ha v t ng ha; - 109 -
+ Ci thin iu kin lao ng v gim nhim mi trng; Do nhng u im trn, mc du i hi vn u t ln, phng php ny vn c ng dng rng ri trong sn xut phi thp cn hin nay.
8.4.1. Thit b
a) S H thng thit b c lin tc gm cc b phn chnh sau: + Thng rt; + Thng rt trung gian; + Thng kt tinh; + B phn rung thng kt tinh; + B phn lm ngui ln hai; + H thng ko phi; + My ct phi. Trn hnh 8.12 trnh by s h thng c lin tc thng ng.
1 2 3 4 5
7 8 9
Hnh 8.12 S h thng thit b c lin tc thng ng 1) Thng rt 2) Thng rt trung gian 3) Thng kt tinh 4) C cu rung thng kt tinh 5) B phn lm ngui ln 2 6) H thng ko phi 7) H thng ct phi 8) C cu h phi 9) H thng vn chuyn phi
- 110 -
b) Phn loi
Cn c vo phng php b tr thit b v ra phi, ngi ta chia ra: + H thng c lin tc thng ng: ton b thit b chnh nh thng kt tinh, h thng trc ko, my ct... b tr theo phng thng ng. c lin tc, b phn ct phi nh k ct phi v h xung h thng vn chuyn b tr theo phng ngang. H thng ny tit kim din tch mt bng, cht lng phi tt (v kim loi ngui u xung quanh, iu kin ni tp cht thun li... ) nhng c hn ch l i hi chiu cao xy dng ln, kh khn trong vic b tr thit b, chi ph xy dng cao v p lc ct kim loi lng ln.
R1 R R2
a)
b)
c)
d)
Hnh 8.13 Phn loi h thng c lin tc a) c thng ng b) c kiu un c) c kiu cong mt bn knh d) ckiu cong theo nhiu bn knh
+ H thng c lin tc kiu un: thng kt tinh thng v b tr theo phng thng ng, phi sau khi ra khi thng kt tinh c ko xung theo phng thng ng mt khong cch nht nh, c my un un cong, sau c nn thng v tip tc ko theo phng ngang. H thng ny gim c chiu cao thit b, phi c th ct theo chiu di ty nhng khi un phi d b nt. + H thng c lin tc kiu cong: phi c un cong ngay sau khi ra khi thng kt tinh hoc cong ngay trong thng kt tinh theo mt bn knh cong hoc mt s bn knh cong k tip. H thng c lin tc kiu cong c chiu cao b tr thit b - 111 -
nh, khng cn phi b tr my un, p lc ct kim loi lng nh, chi ph xy dng thp hn c ng, nhng trong qu trnh c iu kin ni tp cht khng tt, i hi k thut c phc tp hn, trong vic chn bn knh cong c ngha rt ln, nu chn khng ng c th gy ra nt phi trong qu trnh ko.
c) Cc b phn c bn ca h thng thit b
Thng rt: dng vn chuyn thp lng t l n v tr rt. Thng rt thng c ch to c dng hnh tr, v ngoi bng thp bn trong xy gch chu la hoc m bng vt liu chu la. Trn y thng rt c b tr l rt thp, iu chnh qu trnh rt dng c cu cn nt. Thng rt trung gian: dng khng ch tc rt, phn dng kim loi khi c nhiu v tr, tip tc lm ng u kim loi v nhit nc thp. Cu to ca thng rt trung gian trnh by trn hnh 8.13.
6 1 2 3 4 5 7
Hnh 8.13 Thng rt trung gian 1) V 2) Lp aming 3) Lp ct 4) Lp gch chu la 5) L rt 6) Thp lng 7) Cn nt
Thng kt tinh: nhim v ca thng kt tinh l lm ngui kim loi v nh hnh tit din v kch thc phi. Cu to thng kt tinh c dng nh hnh 8.14. Thnh thng kt tinh c ch to bng ng, mt trong l mt tr thng hoc un cong, tit din din ngang l hnh trn hoc hnh vung. Gia thnh ngoi v thnh trong ca thng kt tinh l hp nc lm ngui. Do khi i t trn xung, kim loi ngui v ng c, to thnh lp v rn, lp v rn tng dn chiu dy v co gim kch thc. Khi lp v rn co, s hnh thnh khe h gia kim loi v thnh thng kt tinh, lm gim tc ngui nn phn di ca thng kt tinh thng c cn hn ch khe h. Chiu di thng kt tinh c chn ph thuc vo tc c, phi m bo - 112 -
sao cho chiu dy lp kim loi ng c khi ra khi khun bn di tc dng ca p lc kim loi lng bn trong v lc ko phi. Chiu dy lp v rn khi ra khi khun thng vo khong 8 12 mm.
1 2 4 1 2
a)
b)
Hnh 8.14 Thng kt tinh a) Thng kt kiu thng b) Thng kt tinh kiu cong 1) Thnh thng 2) Ngn nc lm ngui 3) ng dn nc vo 4) ng dn nc ra C cu rung khun: dng rung khun trong qu trnh c, chng li s dnh bm ca kim loi vo thnh thng kt tinh gy ra t phi khi ko. Khi lp v rn mi hnh thnh, nhit ch thp hn nhit kt tinh khong 3 5oC, bn ca thp cn rt thp, di tc dng ca lc ko c th b rn nt v dnh vo thnh thng kt tinh. Khi thng kt tnh dch chuyn xung, lp kim loi dnh bm b y ln do vt nt khng th hnh thnh, khi thi c ko xung s d dng tch khi thnh thng kt tinh v c ko ra. Trong c lin tc, s dng ba phng thc rung khun: rung ng b, rung trt m v rung hnh sin. Khi rung ng b, bnh kt tinh i xung ng b vi phi, sau i ln vi tc gp ba ln tc ko phi. Phng thc ny hin nay t dng v kt cu phc tp do i hi s ng b gia c cu rung v c cu ko phi. Khi rung trt m, bnh kt tinh i xung vi tc cao hn tc ko mt t gi l trt m, sau i ln vi tc kh ln. Phng thc rung ny ph hp vi yu cu ca cng ngh c lin tc, c li cho vic hn gn cc vt nt lp v v cho php nng cao tc ko. Khi rung hnh sin, quan h gia tc rung v thi gian c dng hnh sin, u im ca phng thc rung ny l s thay i tc trong qu trnh rung - 113 -
chm, khng gy xung lc, kt cu rung n gin, do hin nay c s dng rt ph bin. Thit b lm ngui ln hai: khi ra khi bnh kt tinh nhit mt ngoi ca thi cn rt cao 1000 1100oC,v bn trong vn cn kim loi lng tip tc kt tinh. thi c ngui nhanh v kt tinh hon ton, ngi ta b tr h thng vi phun nc phun trc tip ln mt ngoi thi. Trong vng ny cng b tr cc trc ln nn thng thi c trnh hin tng cong vnh thi. Tc phun ca nc lm ngui ln hai khng c qu cao trnh bn te, nhng cng khng c qu thp trnh nc tip xc lu vi mt thi b ha hi nhiu, to thnh lp hi nc trn mt thi lm gim tc lm ngui. Trong vng lm ngui ln hai, lng nhit truyn qua hi nc 33%, qua nc 25% v trc ln 17%, phn cn li truyn nhit bng bc x ra khng kh. H thng trc ko v nn thng: m bo ko phi ra khi thng kt tinh theo tc c yu cu v nn thng phi. ko phi ngi ta dng h thng cc trc ln, dn ng t cc ng c ring l hoc phi hp nhiu trc cng mt ng c qua cc b truyn. Tc ko thng vo khong 6 m/pht. My ct: m bo qu trnh c lin tc, khi phi t mt chiu di nht nh cn phi tin hnh ct phi. Hin nay ct phi ngi ta dng ph bin thit b ct bng kh. Thit b ct c gn trn h thng xe ln, khi phi t chiu di cn thit, c cu kp phi gn trn xe ln tin hnh kp cht phi, lm cho xe ln mang thit b ct chuyn ng cng vi phi v ct phi. Khi phi c ct xong, c cu kp phi nh ra v xe ln chuyn ng tr li v tr ban u.
8.4.2. S kt tinh ca kim loi khi c lin tc
Qu trnh kt tinh ca thi c lin tc th hin trn hnh 8.15. Khi kim loi lng qu nhit c rt vo thng kt tinh tip xc trc tip vi thnh thng kt tinh lm bng ng, bn ngoi c nc lm ngui nn ngui nhanh v mt dn nhit qu nhit. Khi lp ngoi t n nhit kt tinh, th qu trnh kt tinh xy ra v lp kim loi rn hnh thnh. Tip tc dch chuyn xung pha di, kim loi - 114 -
lng tip tc c lm ngui v kt tinh, chiu dy lp kim loi kt tinh tng dn, khi lp kim loi kt tinh bn, chng c p lc ca kim loi lng bn trong th bt u co, hnh thnh nn khe h gia kim loi v thnh thng kt tinh, lm cho tc ngui gim xung. Khi ra khi thng kt tinh, n vng lm ngui th hai, nh s lm ngui trc tip ca nc, tc ngui tng ln v qu trnh kt tinh xy ra nhanh cho n khi phi c kt tinh hon ton.
Nc ra 1
3 Nc vo
2 4
Hnh 8.15 Qu trnh kt tinh ca thi c 1) Kim loi lng 2) Kim loi rn 3) Thng kt tinh 4) Vng lm ngui ln hai
Trong thng kt tinh, tc lm ngui ph thuc rt ln vo s tip xc gia kim loi v thnh thng kt tinh. Nhit tr ca kim loi rn vo khong 1%, nhit tr tip xc gia kim loi rn vi thnh thng kt tinh vo khong 1%, nhit tr ca thnh thng kt tinh bng ng vo khong 0,2 0,3%, nhit tr tip xc gia thnh thng kt tinh vi nc vo khong 1%, nhit tr ca khe h rt ln vo khong 70 80%. Bi vy, tng tc ngui trong thng kt tinh cn hn ch khe h bng cch to cn ngc mt trong thnh thng kt tinh (thng ch to vi cn 1%) hoc ph kn khe h bng vt liu dn nhit tt hn khng kh. - 115 -
Trong vng lm ngui ln hai, nh s tip xc trc tip gia kim loi v nc, s bc hi ca nc, tc lm ngui nhanh, kim loi kt tinh nhanh v cui cng ng c hon ton. Do chnh lch nhit gia mt ngoi v bn trong ln c th gy ra ng sut nhit lm nt b mt thi, do trong vng lm ngui ln hai cn b tr lm ngui tng dn t trn xung. xc nh chiu cao ct kim loi lng gia, trn c s xc nh chiu cao thng kt tinh v chiu di vng lm ngui ln hai, cn xc nh tc kt tinh ca thi. Tc kt tinh ca thi xc nh qua chiu dy lp kim loi kt tinh v c th tnh c theo cng thc (8.1), vi K = 13 20 mm/pht1/2 khi trong thng kt tinh v K = 25 28 mm/pht1/2 trong vng lm ngui ln hai. i vi phi trn ng knh D, c th xc nh c thi gian kt tinh hon ton theo cng thc:
D = 50,8
2
(pht)
(8.3)
Tnh c thi gian ng c hon ton, ta c th xc nh c chiu cao ct kim loi lng gia thi khi c lin tc:
L = v.
(mm)
(8.4)
Vi v l tc ko thi (hay tc c) tnh bng mm/pht. Khi c lin tc, do c lm ngui nhanh v rt lin tc, kim loi c cu trc tinh th ht nh v khng c l co, r kh phn tn, nhng tm do s b ngt kh khn nn thng xut hin r xp ng tm. So vi c khun, cht lng thi c bng phng php c lin tc cao hn.
8.4.3. Cng ngh c thi lin tc
a) Nhit c: nhit c l nhit nc thp khi rt khun, c chn da vo mc thp, kt cu thng kt tinh v tc c. b) Thao tc chun b: tin hnh chuyn thp lng t l n thng rt trung gian, kim tra nhit nc thp. Trc lc rt thp lng phi tin hnh kim tra bnh kt tinh, h thng nc lm ngui bnh kt tinh, lm ngui ln hai (lu lng, p lc nc,
- 116 -
v tr vi phun) v s hot ng bnh thng ca cc thit b rung thng kt tinh, thit b ko, nn, ct phi. Sau tin hnh lp u thanh dn vo thng kt tinh. c) Thao tc c: tin hnh rt kim loi t thng rt trung gian vo thng kt tinh. Ch mt thi gian kim loi kt tinh v bm chc vo u thanh dn v mt ngoi thi bt u hnh thnh lp kim loi bn th tin hnh khi ng h thng ko ko phi. Sau khi tin hnh ct u thi th vn hnh c cu ct ct phi theo chiu di yu cu.
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Mc lc Chng I. Khi qut chung 1.1. Khi nim v phn loi thp 1.1.1. Khi nim 1.1.2. Phn loi thp 1.1.3. K hiu thp 1.2. Lu trnh sn xut thp 1.3. Phn loi l luyn thp Chng II. Nguyn vt liu dng luyn thp 2.1. Nguyn vt liu 2.1.1. Nguyn vt liu kim loi 2.1.2. Cht oxy ha 2.1.3. Cht to x 2.1.4. Cht tng cacbon 2.1.5. Vt liu chu la 2.2. Tnh ton thnh phn phi liu Chng III. L thuyt qu trnh luyn thp 3.1. L thuyt v s oxy ha v hon nguyn 3.2. S oxy ha v hon nguyn cc nguyn t 3.2.1. S oxy ha v hon nguyn st 3.2.2. S oxy ha v hon nguyn mangan 3.2.3. S oxy ha v hon nguyn silic 3.2.4. S oxy ha v hon nguyn cacbon 3.2.5. Kh phtpho 3.2.6. Kh lu hunh 3.2.7. Kh kh 3.2.8. Tp cht phi kim 3.3. X trong qu trnh luyn thp 3.3.1. Ngun gc v thnh phn ca x luyn thp - 119 5 5 5 5 7 8 9 10 10 10 13 14 15 16 19 24 24 26 26 26 29 32 34 36 37 39 39 39
3.3.2. Cc tnh cht ca x luyn thp 3.4. Cn bng nhit trong qu trnh luyn thp 3.4.1. Ngun nhit cung 3.4.2. Ngun nhit chi Chnng IV. Luyn thp trong l in h quang 4.1. c im v phn loi 4.1.1. c im 4.1.2. Phn loi 4.2. Thit b 4.2.1. Cu to chung v nguyn l lm vic 4.2.2. Bung l 4.2.3. Thit b nng h in cc 4.2.4. C cu nghing l 4.2.5. Thit b in 4.2.6. in cc 4.3. Cng ngh nu luyn 4.3.1. Nguyn vt liu 4.3.2. Cng ngh luyn thp trong l in h quang baz 4.3.3. Tinh luyn ngoi l Chng V. Luyn thp trong l in cm ng v mt s l in khc 5.1. c im v phn loi 5.1.1. c im 5.1.2. Phn loi 5.2. Thit b 5.2.1. S cu to v nguyn l lm vic 5.2.2. Cc b phn c bn ca l 5.3. 5.4. Cng ngh nu luyn Thit b v cng ngh nu thp trong mt s l in khc
41 45 45 45 46 46 46 46 46 46 48 51 52 52 55 58 58 58 61 63 63 63 63 63 63 65 70 70 70
5.3.1. Nu thp trong l in x - 120 -
5.3.2. Nu thp trong l in h quang chn khng Chng VI. Luyn thp trong l thi 6.1. 6.2. c im v phn loi Luyn thp trong l thi sn
71 73 73 75 75 76 85 86 86 88 89 89 89 89 89 91 91 92 94 94 94 95 97 98 99 100 100 103 106
6.2.1. Cu to l 6.2.2. Cng ngh luyn thp trong l thi sn baz 6.2.3. Cng ngh luyn thp trong l thi sn axit 6.3. Luyn thp trong l LD 6.3.1. Cu to l 6.3.2. Quy trnh luyn thp trong l LD Chng 7. Luyn thp trong l mactanh 7.1. 7.2. c im Thit b
7.2.1. Cu to 7.2.2. Nguyn l lm vic 7.3. Cng ngh nu thp trong l mactanh 7.3.1. Nu thp trong l mactanh baz 7.3.2. Nu thp trong l mactanh axit Chng 8. c phi thp 8.1. 8.2. Phn loi v c im L thuyt v qu trnh kt tinh
8.2.1. iu kin hnh thnh v ln ln ca tinh th 8.2.2. Qu trnh kt tinh v ta nhit 8.2.3. Qu trnh kt tinh v co ngt th tch 8.2.4. Qu trnh kt tinh v thin tch 8.3. Thit b v cng ngh c khun 8.3.1. Khun c 8.3.2. Cu trc thi thp 8.3.3. Cng ngh c khun - 121 -
8.4.
c lin tc
109 110 114 116 118 119
8.4.1. Thit b 8.4.2. S kt tinh ca kim loi khi c lin tc 8.4.3. Cng ngh c thi lin tc Ti liu tham kho Mc lc
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Ti liu tham kho 1. Gio trnh c thp. B mn c, i hc Bch Khoa H Ni - 1985. 2. Trn Vn Dy. K thut l in luyn thp. Nh xut bn khoa hc k thut H Ni - 2006. 3. Ng Tr Phc, Nguyn Sn Lm. Thit b v cng ngh c phi thp. Nh xut bn Bch Khoa H Ni - 2006. 4. Phan T Phng. S tay c thp. Nh xut bn Khoa hc K thut. H Ni -1997. 5. V.M. Trurin, P. N. Buulia. Vprx theori lichinx prtxecxp. Gxuarstvenoe Hautrn-tecnictrecskoe izachienxtv mashinostroenie lichetur. Moskva - 1980.
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Giao Trinh Cong Nghe Va Thiet Bi Luyen Thep - Hoang Cong Minh - 100306 - 1

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Giao Trinh Cong Nghe Va Thiet Bi Luyen Thep - Hoang Cong Minh - 100306 - 1

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I HC NNG TRNG I HC BCH KHOA

HONG MINH CNG

Gio trnh CNG NGH V THIT B LUYN THP

Chng I KHI QUT CHUNG

Hnh 1.1 Gin ko ca thp

Hon nguyn trc tip

Hon nguyn th lng

Hon nguyn th rn St thp ph

Gang luyn thp X Gang c

Hnh 1.1 S lu trnh sn xut thp

Chng II NGUYN VT LIU DNG LUYN THP

2.1.1. Nguyn vt liu kim loi

0,60 1,20 0,5 0,80 0,8 0 1,30

Fersilic 45 Si 45 Fersilic 75 Si 75 Fersilic 90 Si 90

0,260,50 0,501,0 1,12,0 2,14,0 4,16,5 6,68,0

2,0 2,53,0 2,53,0 2,53,0 2,05,0 2,05,0

0,1 0,10 0,10 0,10 0,07 0,07

0,04 0,04 0,04 0,04 0,04 0,04

p sut s dng (kG/cm2) 5 10 6 12 3

Hoc: Gang luyn P v S trung bnh : 35 20 %; - 21 -

i vi thp hp kim, chn: + + + + + St thp vn : 70 90 %;

Hoc: Ph phm thp hp kim: 60 70%; Ph phm thp cc bon : 10 20%;

Fe 2 O 3 + Fe 3FeO Khi s xy ra phn ng t chy cc tp cht v cacbon:

Chng III L THUYT QU TRNH LUYN THP

Z 0 - s thay i nng lng t do ca h thng; T H 0 - s thay i nhit hm ca h thng (entanpi). T

S0 - s thay i entrpi ca h thng; T

kh khi n cn bng vi oxyt v kim loi th gi l p sut phn ly ca oxyt v ta c:

Z 0 kj/mol O2 298 1000oC - 1068 1600oC - 942,11

H0 298 kj/mol O2 - 1270,27

-624,67 - 399,10 - 306,27 -190,92

- 535,91 - 313,13 -190,54 - 103,84

- 779,58 - 540,10 - 339,24 - 339,24

3.2. S oxy ha v hon nguyn cc nguyn t 3.2.1. S oxy ha v hon nguyn st

(3.5) (3.6) (3.7)

[Fe] + [O] = FeO xFeO = y[FeO] + z(FeO )

Khi a trc tip qung vo hp kim lng:

(3.8) (3.9) (3.10)

x (Fe 2 O 3 ) + x[Fe] 3x.FeO

+ (Fe 2 O 3 ) khuch tn qua x n b mt tip xc gia x v kim loi v xy ra phn ng:

3x.FeO = 3y[FeO] + 3z(FeO) Vi

[Mn ] + [FeO] = (MnO ) + [Fe]

[Mn ] + (FeO) = (MnO ) + [Fe]

khng i, nu tng nhit th lng Mn cn li trong kim

(3.20) (3.21) (3.22)

3.2.3. S oxy ha v hon nguyn silic

(SiO 2 ) hoc (SiO ) v h Si - O chuyn bin theo hai h thng:

siO2 ( nhit > 1500oC) siO2 ( nhit < 1500oC)

[Si] + 2[FeO] = (SiO ) + 2[Fe]

[Si] + 2(FeO) = (SiO ) + 2[Fe]

lg K Si = T (3.29) suy ra:

19.057 11,1 T 1 N (SiO ) . K Si N (2FeO )

(FeO) v to thnh hp cht phaialit: (SiO 2 ) + 2(FeO) = (Fe 2SiO 4 )

V sau, ty thuc theo mc ha tan ca vi trong phaialit m oxyt st s

(Fe 2SiO 4 ) + 2(CaO ) = (Ca 2SiO 4 ) + 2(FeO)

[Si] + 2[FeO] = (SiO ) + 2[Fe]

(SiO 2 ) + 2[C] = [Si] + 2{CO} (SiO 2 ) + 2[Fe] = [Si] + 2(FeO)

Hoc theo h hai phng trnh c phn ng trung gian:

[FeO] + [C] = [Fe] + [CO] [CO] = {CO}